General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

Some general repair information that applies to several procedures throughout this manual is summarized here. They apply to this repair manual.

Guided Fault Finding, On Board Diagnostics (OBD) and Test Instruments

• Determine the cause of the malfunction as accurately as possible using Guided Fault Finding  , OBD  and Test Instruments  before starting any repairs on the transmission see Vehicle Diagnostic Tester.

Oil, Environmental and Disposal Regulations

• Handle ATF, axle oil and other fluids with care.
• Dispose of drained ATF properly.
• Follow the legal environmental and disposal regulations.
• Follow the information provided on oil packaging.

Special Tools and Equipment

For a complete list of special tools used in the Repair Manual refer to Workshop Equipment and Special Tools.

Transmission

• Follow the rules for clean working conditions when working on the transmission. Refer to CLEAN WORKING CONDITIONS .
• Do not run the engine or tow the vehicle when the center differential housing is removed or when there is no ATF.
• Check the fluid levels after installation and fill if necessary: ATF refer to ATF LEVEL, CHECKING and gear oil. Refer to GEAR OIL, CHECKING LEVEL . Capacities (refer to CAPACITIES ), Specifications, (refer to the Parts Catalog).
• It is necessary to check the parking lock emergency release after performing any work on it or after removing and installing the transmission. Refer to EMERGENCY RELEASE FROM P .

O-rings, Shaft Seals, Seals

• O-rings, shaft seals and seals must be replaced.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• Thoroughly clean housing joint surfaces before assembling.
• To install, thinly coat shaft seals along outer circumference and on sealing lip with ATF.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Always only use approved ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.
• The open side of the shaft seals point toward the fluid to be sealed in.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Check the fluid levels after installation and fill if necessary: ATF refer to ATF LEVEL, CHECKING and gear oil. Refer to GEAR OIL, CHECKING LEVEL . Capacities (refer to CAPACITIES ), Specifications. Refer to the PartsInformation

Bolts and Nuts

• Loosen the bolts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be tightened in steps according to the specified tightening sequence and method.
• Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
• Replace the self-locking nuts and bolts.
• Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Install the bolts with Locking Fluid:AMV 185 101 A1  .
• Threaded holes used for self-locking bolts or bolts coated with locking fluid must be cleaned, for example with a thread tap. Otherwise there is a risk that the bolts will shear the next time they are removed.
• The tightening specifications stated apply to non-oiled nuts and bolts.

Fasteners

• Do not overstretch the circlips.
• Replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.

Bearings

• Install needle bearings with lettered side (thicker metal) racing the fitting tool.
• Insert bearing with axle oil or ATF, depending on installation location.
• Do not interchange the outer or inner races of bearings of the same size.
• Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.

Adjusting Shims

• Measure the adjusting shims at several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.
• Check for burrs and damage. Only install perfect shims.