Tightening Specifications

• Refer to OVERVIEW - INTERMEDIATE HOUSING 
• Refer to OVERVIEW - DISC SET I AND II 

Tip:

If disc set "I" is replaced, the circlip must be redetermined for bearing "E".

If disc set "II" is replaced, the circlip must be redetermined for bearing "G".

• Disc set "II" is locked with :T40387/3  .
• Place the chain and guide rail in the installation position.

-- Check for wear. Refer to WEAR, CHECKING .

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-- Carefully insert disc set "I" -3- together with disc set "II" -2- in the roller bearing and insert the spline.

-- Clip the guide rail -2- on the oil pipe -1- securely.

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-- Insert the :T40387/2  all the way into disc set "II" and connect to the :VAS6213  .

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-- Build up a vacuum with the hand vacuum pump.

• The disc set is open.

-- Remove the lock for disc set "II" :T40387/3 

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-- Reduce the vacuum slowly, and remove the :VAS6213  with the : T40387/2  .

• The disc set closes, the chain tensions itself.

-- Bring the oil guide piece "II" -1- into the installation position by carefully inserting the connecting piece -arrow-.

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-- Insert the oil guide piece "I" -1- while engaging the retaining pins -arrows- in the holes on the plastic pan.

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-- Mount the intermediate housing seal -2-.

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-- Make sure the alignment sleeves -1 and 3- are installed. Insert them if necessary.

-- Screw in the :T40288  .

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-- Insert the :T40387/1-4  with the :T40387/1-6  in bearing "G" -1- and secure with the :T40387/1-8  .

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-- Mount the intermediate housing, while guiding in the oil guide piece "II", suction jet pump and the locking pin for the parking lock.

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-- Tighten the :T40387/1-1  with the :T40387/1-5  on the intermediate housing with the bolts -arrows- to 20 Nm.

• During the following procedure, always continue to check if the locking pin for the parking lock can move freely. Turn at the dual mass flywheel if necessary.

-- Press the intermediate housing on bearing "G" with the :T40387/1-7  ; counterhold on the :T40387/1-6  while doing so.

-- Remove the nut from the spindle, unscrew the puller and remove.

• The puller sleeve with the threaded spindle and circlip remain installed.

-- FIND THE RESPECTIVE CIRCLIP -1- IN THE "CIRCLIPS FOR BEARING G" REPAIR KIT, WHICH CAN STILL BE INSERTED DIRECTLY IN THE GROOVE -ARROW- ON BEARING "G" -2-. 

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-- Mount the circlip.

Tip: 

If disc set "II" with bearing "G" has to be slid downward again due to a loose bearing seat, disc set "II" with bearing "G" must be pushed upward by hand at the threaded spindle to determine the correct circlip.

-- Remove the :T40387/1-8  , :T40387/1-6  with :T40387/1-4  from the bearing "G" -1-.

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-- Tighten the bolts -arrows- for the intermediate housing.

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-- Turn the transmission 180° on the :VAS6095A  .

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• The open side will now face downward, disc set "I" slides to the stop in bearing "E".

-- Select the respective circlip -1- from the repair kit "Circlips for Bearing E", which can still be slid straight into the groove of disc set "I" above the bearing "E" -2-.

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-- Install the circlip with locking ring pliers.

-- Turn the transmission back 180° to its original position on the :VAS6095A  .

• The open side of the transmission will now face upward.

-- Insert the oil pipe -arrow- carefully until it stops.

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• The oil pipe is inserted correctly if it protrudes approximately 4.5 mm out of the housing.

-- Remove the cable tie -arrow B- on the gearshift shaft.

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• The open side of the sensor wheel faces upward.

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-- Using the :T40387/11  , press the sensor wheel -arrow- all the way onto the shaft for disc set "II".

• The open side of the sensor wheel faces upward.

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-- Using the :T40387/10  , press the sensor wheel -arrow- all the way onto the shaft for disc set "I".

-- Install the hydraulic control unit. Refer to HYDRAULIC CONTROL UNIT, REMOVING AND INSTALLING .

-- Install the Transmission Control Module -J217-. Refer to TRANSMISSION CONTROL MODULE, REMOVING AND INSTALLING .

-- Install the end cover. Refer to END COVER, REMOVING AND INSTALLING .