General Repair Information
WARNING: This page is about a different variant/trim than selected.
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.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points are summarized here. They apply to this service information.
Special Tools and Equipment
Complete list of special tools used
Transmission
- Servicing. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .
- Allocate bolts and other components according to transmission code . Refer to TRANSMISSION/ENGINE ALLOCATION .
- Check the transmission fluid level when replacing the manual transmission and fill if necessary. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
- Capacities and specifications. Refer to CAPACITIES .
- Always clean the connection locations and the area around them before loosening.
- When installing transmission, make sure that the alignment bushings are fitted correctly.
Sealant
- Thoroughly clean the housing joint surfaces before applying the sealing compound.
- Apply the Sealant AMV 188 001 02 evenly and not too thick.
- Do not allow any Sealing Compound to get into the ventilation holes.
O-rings, Shaft Seals, Sealing Rings and Seals
- O-rings, gaskets 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.
- Before installing the shaft seal lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with Grease G 052 128 A1.
- 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 insertion depth tolerances).
- Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
- After replacing the seals and sealing rings, check the transmission fluid level and fill if necessary. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
Fasteners
- Do not overstretch the circlips.
- Always replace damaged or stretched circlips.
- The circlips must fit completely inside the groove.
- Replace the adapter sleeves. Installed position: the slit -A- should align with the line of force -arrow-.
Bolts and Nuts
- Loosen the bolts and nuts opposite the tightening sequence.
- Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
- Parts which are particularly sensitive to distortion must be kept straight when removing and installing; loosen or tighten diagonally in stages.
- The tightening specifications stated apply to non-oiled nuts and bolts.
- Always replace 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.
Clutch Mechanism
- When removing transmission, remove the clutch slave cylinder without opening the lines.
- If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the clutch slave cylinder. The clutch slave cylinder will get damaged.
- If the clutch pedal does not return to the starting position (rest position) after recoupling it, bleed the clutch system. Additional information. Refer to CLUTCH MASTER OR CLUTCH SLAVE CYLINDER, REMOVAL AND INSTALLATION INFORMATION .
- To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.
- Only use compressed air to clean the clutch module.
- Change the fluid for the clutch system at the same interval when changing the brake fluid for the brake system. Refer to CLUTCH MECHANISM, BLEEDING .