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Explanation of the terms used in this workshop manual > < Information for the automatic gearbox 09G

Octavia Mk2

Repair instructions
Repair instructions
Scrupulous care and cleanliness as well as the proper tools are essential requirements for carrying out proper and successful gearbox repairs. Obviously, the generally valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here. They apply to this workshop manual.
Special tools
List of the special tools used in the workshop manual → Workshop Equipment Electronic Catalogue.
Gearbox
t  Each time a gearbox is installed, basic settings are required.
t  Do not run the engine or tow the vehicle when the oil pan of the gearbox has been removed or without ATF filling.
t  If the automatic gearbox is replaced, check ATF level if necessary top up with ATF → Chapter. Capacity and specification → Chapter.
t  Secure the torque converter against dropping out when the gearbox is removed.
t  Thoroughly clean the connection points and their surroundings before releasing.
t  Before installing the gearbox check the fitting position of the torque converter → Chapter.
t  When installing, take care with the correct positions of dowel sleeves in the engine.
t  Place removed parts on a clean surface and cover. Use foil and paper. Do not use fuzzy cloths!
t  Carefully cover or close opened components if the repair is not completed immediately.
t  Only install clean parts. Remove spare parts from their wrapping immediately before fitting.
   
The ATF filler tube is no longer available on gearboxes as of production date 06.06 -arrow-.
O-rings, gasket rings, gaskets
t  Always replace O-rings, gaskets and gasket rings.
t  After removing gaskets, examine the contact surface in the housing or on shafts for burrs or damage, and correct if necessary.
t  Depending on location, before fitting a gasket ring, smear the outer surface and sealing lip thinly with ATF or axle oil.
t  Before inserting the O-rings coat with ATF to prevent the rings being squashed during installation.
t  The open side of the sealing rings is turned towards the oil.
t  Never use other lubricants in the ATF area.
  N37-10325
t  Radial shaft seals - before mounting lightly oil at outside diameter and fill half the space between the sealing lips -arrow- with sealing grease -G 052 128 A1-.
t  After installation, inspect ATF level and if necessary top up → Chapter.
Locking elements
t  Do not over-extend the circlips, if necessary replace.
t  Circlips must be positioned in the base of the groove.
Screws, nuts
t  Slacken and tighten screws or fixing nuts of covers and housings crosswise.
t  Do not twist particularly sensitive parts - e.g. the slide valve body - and slacken and tighten diagonally across in stages.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Clean the thread of the screws that are inserted with a locking agent with a wire brush. Insert bolts with locking agent -AMV 185 101 A1-.
t  Clean all threaded holes into which self-locking bolts are inserted, using a thread tap to remove locking agent residues. Otherwise there is a risk that the bolts will shear at the next disassembling.
t  Replace the self-locking screws and nuts.
t  Bolts that still need to be turned at a certain angle after tightening must always be replaced.
Electrical components
This electrostatic charge can lead to operational problems after touching the electrical components of the gearbox and the shift mechanism.
–  Touch an earthed object - e.g. a metal water pipe or a lift platform - before working on the electrical components. Do not touch the contacts of the plugs and the »»open«« electrical components.
Targeted fault-finding
Before repairing the automatic gearbox 09G, try to determine the origin of the damage as accurately as possible using the → Vehicle diagnostic tester in the „Targeted fault-finding“ mode.
  N32-0001

Explanation of the terms used in this workshop manual > < Information for the automatic gearbox 09G