General Information: Components
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Transmission
- Always clean the connection locations and the area around them before loosening.
- When replacing or repairing a manual transmission, check the fluid level and fill if necessary. Refer to [For engine(s) CAUA] General Information .
- Use the transmission code to determine capacities and specifications. Refer to [For engine(s) CAUA] Specifications .
Sealant
- Thoroughly clean the housing joint surfaces before applying the sealing compound.
- Apply sealing compound 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, Seals
- O-rings, shaft seals and seals must be replaced.
- After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
- Thoroughly clean housing joint surfaces before assembling.
- Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with grease G 052 128 A1.
- 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).
- Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
- After replacing the seals and the sealing rings, check the transmission fluid level and fill if necessary. Refer to [For engine(s) CAUA] General Information .
Fasteners
- Do not overstretch the circlips.
- Installed position for some of the locking rings: The ring is narrower on top and this shape matches its installed location. This makes it easier for the pliers to grab the circlip when removing and installing it.
- Always replace damaged or stretched circlips.
- The circlips must fit completely inside the groove.
- Replace the adapter sleeves. Installed position: Slit -A- should be in line 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 diagonally and in steps 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. Next, use locking compound AMV 185 101 A1 to install the bolts.
- Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
Adjusting Shims
- Measure the adjusting shims at several locations with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
- Check for burrs and damage.
- Only install perfect shims that have never been damaged.
Bearings
- Set needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward drift.
- Insert all the bearings in transmission with gear oil.
- Heat inner races of tapered roller bearings to approximately 100 °C (212 °F) with the inductive heat unit VAS 6414 before installing. Press on to the stop when installing, so there is no axial clearance.
- Warm inner race for needle and roller bearings to 130 °C (266 °F) max.
- Do not interchange outer and inner bearing races with those from other bearing of the same size. The bearings are paired.
- Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.
Gears, Synchronizer Hubs, Selector Gear Inner Races
- To install, heat gear wheel inner race to approximately 100 °C (212 °F) with the VAS 6414.
- Heat the synchronizer hub to approximately 100 °C (212 °F) with the VAS 6414 before installing. Press on as far as the stop when installing so there is no axial play.
- Heat the gears to approximately 150 °C (302 °F) with the VAS 6414 before installing. Press on to the stop when installing, so there is no axial clearance.
- Pay attention to the installed location.
Selector Gears
- After assembly, check selector gears of 1st through 6th gear for axial play of 0.15 to 0.50 mm or more of movement.
Input Shaft
- If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel -arrow-, then replace both the input shaft and the needle bearing. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING .
- Replace the driveshaft. Refer to TRANSMISSION .
- Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate if necessary. Refer to the appropriate service information .
Synchronizer Rings
- Do not interchange them. When reusing synchronizer rings, always install to the same gear wheel.
- Check for wear and replace if necessary.
- Install coated with transmission fluid.
- Check coated friction surfaces -arrows 2- from intermediate ring -B- for damage (flat areas, disintegrating areas or carbon layer).
- Check the inner friction surface -arrow 1- of the synchronizer ring -A- and the outer friction surface -arrow 4- of the inner race -C- for grooves and scoring.
- On inner races -C- with coated friction surfaces -Arrow 3-, check coating for damage (disintegrating carbon layer).
Damage on the Selector Gears and Locking Collars
- Damage to the synchronizer ring or gear wheel:
A - Worn clutch spline camber on the synchronizer ring or gear wheel
- For comparison: synchronizer ring or gear wheel not damaged:
B - Undamaged clutch spline camber on the synchronizer ring or gear wheel
- Picture of damage on the locking collar:
C - Worn longitudinal inner spline camber and the locking collar
- For comparison: locking collar undamaged
D - Undamaged longitudinal inner spline camber and the locking collar
- Synchronizer rings coated with carbon must be replaced together with the locking collar. The gear wheels must be replaced as well depending on the amount of wear.