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| Proper tools and the maximum possible care and cleanliness are essential for satisfactory repairs to the transmission units. The usual basic safety precautions also naturally apply when carrying out repair work. |
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| To avoid unnecessary 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 specified. Otherwise, there is a risk of problems occurring in the gearbox hydraulics. |
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| The open side of the oil seal should face the side containing the fluid. |
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| When installing a new oil seal, position the seal such that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth tolerances). |
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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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