General Repair Information: Notes

• The highest level of care and cleanliness along with tools that function properly are required to ensure a proper and successful transmission repair. Of course the general safety precautions also apply when carrying out repair work.
• Some general repair information that applies to several procedures throughout this manual is summarized here. They apply to this repair manual.

Guided Fault Finding, 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 using the Vehicle Diagnostic Tester.

Special Tools

For a complete list of special tools used in the repair manual, refer to Workshop Equipment and Special Tools.

Oil, Environmental and Disposal Regulations 

• Handle transmission fluid, gear oil and other fluids with care.
• Dispose of drained fluid properly.
• Follow the legal, environmental, and disposal regulations.
• Follow the instructions listed on the fluid packaging.

Transmission 

• Do not run the engine or tow the vehicle when the transmission fluid pan is removed or when there is no transmission fluid.
• Thoroughly clean the connection points and the surrounding area before loosening.
• During installation, make sure the alignment sleeves are fitted correctly.

O-rings, Shaft Seals, Seals 

• Always replace the O-rings, shaft seals and seals.
• After removing the seals, examine the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
• Thoroughly clean the housing separating surfaces before assembling.
• Always replace paper gaskets, completely remove an old seal and thoroughly clean the sealing surfaces.
• When installing shaft seals, apply transmission fluid to the outer edge and sealing lip.
• Coat the O-rings with transmission fluid or Vaseline before inserting to prevent them from being crushed during assembly.
• Do not use any other lubricants in the transmission fluid area. Otherwise there is a danger of the hydraulic transmission control malfunctioning.
• The open side on the shaft seals faces the fluid to be sealed off.
• 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 offset tolerance).
• Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

Circlips 

• Do not stretch the circlips.
• Replace damaged or stretched circlips.
• The circlips must rest at the bottom of the groove.

Bolts and Nuts 

• Loosen the bolts opposite the tightening sequence.
• Nut and bolts from covers and housings should be loosened and tightened diagonally and in stages if no tightening sequence is specified.
• Replace the self-locking nuts.
• Use a wire brush to clean the threads of the bolts that were installed with locking fluid. Then insert the bolts with Locking Fluid:AMV 185 101A1  .
• Use a thread cutter to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.
• Please make sure that the thread pitch is correct so that the proper thread cutter is used during cleaning, and the thread does not get damaged.
• The tightening specifications given apply to unoiled bolts and nuts.