| The maximum possible care and cleanliness and proper tools are essential for satisfactory and successful gearbox repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs. |
| A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They apply to the work described in this Manual. |
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| Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the gearbox. |
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| When renewing the automatic gearbox the ATF → Chapter must be checked and topped up, if necessary. Filling quantities and specification → Chapter. |
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| If gearbox has been removed from vehicle, secure torque converter to prevent it from falling out. |
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| Thoroughly clean all joints and surrounding areas before dismantling. |
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| Before installing gearbox check position of torque converter → Chapter. |
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| When installing gearbox, ensure that dowel sleeves are fitted correctly. |
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| Place removed parts on a clean surface and cover them over. Use sheeting and paper. Use lint-free cloths. |
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| Carefully cover or seal open components if repairs cannot be carried out immediately. |
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| Only install clean components: do not remove replacement parts from packaging until just before installation. |
| O-rings, oil seals, gaskets |
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| Always install new 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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| 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 seals with ATF before installing. |
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| Lightly lubricate O-rings with ATF before installation to prevent them getting crushed during assembly. |
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| Do not use any other lubricants where ATF is used. Otherwise, there is a risk of problems occurring in the gearbox hydraulics. |
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| The open side of the oil seals faces toward the side with fluid filling. |
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| After installing, check ATF level, rectify as necessary. |
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| Do not overstretch retaining rings/circlips; renew if necessary. |
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| Retaining rings/ 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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| Clean the threads of bolts which are secured by a locking fluid with a wire brush. Then lubricate bolts with locking compound -AMV 185 101 A1- again before fitting. |
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| The tightening torques stated apply to non-oiled nuts and bolts. |
| Guided fault finding, vehicle self-diagnosis and testing system |
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