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| Before working on the vehicle while the engine is running, shift the selector lever into position “P” and apply the handbrake. |
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| When the engine is running, the exhaust system must always be connected to the exhaust gas extractor. |
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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. |
| 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. |
| Environmental and waste disposal regulations for oil |
| ATF, gear oil and any other type of oil must be handled with care. Dispose of drained oil properly. Always adhere to statutory environmental and waste disposal regulations. |
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| Observe rules for cleanliness when working on gearbox → Chapter. |
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| The engine must not be run and the vehicle must not be towed with the end cover removed or without ATF in the gearbox. |
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| Only install clean components: do not remove replacement parts from packaging until just before installation. |
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| After installing, the following fluid levels must be checked and topped up if necessary: ATF in planetary gearbox → Chapter and gear oil in front final drive → Chapter. Capacities and specifications → Chapter. |
| 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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| Lightly lubricate the outer circumference and sealing lip of oil 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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| Use only ATF for parts running in ATF. Other lubricants will cause malfunction of 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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| After installing, the following fluid levels must be checked and topped up if necessary: ATF in planetary gearbox → Chapter and gear oil in front final drive → Chapter. Capacities and specifications → Chapter. |
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| Loosen bolts in reverse sequence to the specified tightening sequence. |
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| Bolts and nuts used to secure covers and housings must be tightened in steps according to the specified tightening sequence and method. |
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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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| The tightening torques stated apply to non-oiled nuts and bolts. |
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| Always renew self-locking bolts and nuts. |
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| Use a wire brush to clean the threads of bolts which are secured with locking fluid. Then apply AMV 185 101 A1 when inserting. |
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| Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed. |
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| Do not over-stretch circlips. |
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| Always renew circlips which have been damaged or over-stretched. |
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| Circlips must be properly seated in the base of the groove. |
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| Install needle bearings so the lettering (side with thicker metal) faces towards the installing tool. |
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| Lubricate bearings with gear oil or ATF, depending on fitting location. |
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| Do not interchange inner or outer races of bearings of the same size. |
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| Always renew the tapered roller bearings on one shaft together and use new bearings from a single manufacturer. |
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| Use a micrometer to measure the shims at several points. Tolerance variations make it possible to obtain the exact shim thickness required. |
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| Check for burrs and damage. Install only shims which are in perfect condition. |
| Before commencing any repair work, always perform the Guided Fault Finding procedure using vehicle diagnostic, testing and information system -VAS 5051B-. |
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