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| Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. The usual basic safety precautions also naturally apply when carrying out repair work. |
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| To avoid repetition, a number of generally applicable instructions for the various repair procedures are summarised here. They apply to the work described in this Manual. |
| Guided Fault Finding, vehicle self-diagnosis and testing system |
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| Before servicing the gearbox, the exact cause of the failure must be determined using the Guided Fault Finding, Vehicle Self-diagnosis and Test Instruments → vehicle diagnostic tester. |
| Environmental and waste disposal regulations for oil |
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| ATF, gear oil and any other type of oil must be handled with care. |
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| Dispose of drained oil properly. |
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| Always adhere to statutory environmental and waste disposal regulations. |
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| Observe the information shown on the packaging of the oil. |
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| Do not run the engine or tow the vehicle with the oil pan removed or when there is no gear oil in the gearbox. |
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| Thoroughly clean all joints and connections and the surrounding areas before dismantling. |
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| When installing gearbox, ensure that dowel sleeves are fitted correctly. |
| O-rings, oil seals and gaskets |
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| Always renew O-rings, oil seals and gaskets. |
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| After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage. |
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| Thoroughly clean housing joint surfaces before assembling. |
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| Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly. |
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| Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing. |
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| Lightly lubricate O-rings with gear oil or vaseline before installation to prevent them from getting crushed during assembly. |
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| Do not use any other lubricants where gear oil is used. Otherwise there is a risk of malfunctions and/or failure of the gearbox. |
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| The open side of the oil seal should face the side containing the fluid. |
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| After installing, check the gear oil level and rectify as necessary → Chapter. |
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| Do not over-stretch circlips. |
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| Renew circlips which have been damaged or over-tensioned. |
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| Circlips must be properly seated in the base of the groove. |
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| Loosen bolts in reverse sequence to the specified tightening sequence. |
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| Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified. |
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| Renew self-locking nuts. |
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| Use a wire brush to clean the threads of bolts which are secured with locking fluid. Then apply locking fluid -AMV 185 101 A1- to bolt threads before installing. |
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| The tightening torques stated apply to non-oiled nuts and bolts. |
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