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Cleaning norms when working in the gearbox > < Instructions for tow starts and when towing

Leon Mk1

Repair instructions
Repair instructions
Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. Naturally, the normal basic safety regulations should be followed during repairs.
General instructions for certain repair work that appear repeatedly in the Repair Manual are summarised below. They apply for this individual Workshop Manual.
Special tools
The specialist tools that are used in the Repair Manual are indicated in the → "Specialist tools" and "Workshop equipment". files
Gearbox:
t  If the oil sump has been removed or if there is no ATF, the vehicle must not be started or towed.
t  If the automatic gearbox is replaced, the ATF level must be checked and must be topped up if necessary → Chapter . Filling amounts and oil type specifications → Chapter.
t  If the gearbox is removed, the torque converter must be secured so that it does not fall.
t  Thoroughly clean unions and adjacent areas before removing.
t  Before fitting the gearbox, the installation measurements for the torque converter must be checked → Chapter.
t  When installing the gearbox, ensure that dowel sleeves between the engine and gearbox are correctly located.
t  Place removed parts on a clean surface and cover them to prevent them from getting dirty. Use foil or paper. Use only lint-free cloths.
t  Carefully cover or store opened components if repairs cannot be carried out immediately.
t  Only fit clean parts: only remove replacement parts from packaging immediately prior to installation.
Gearboxes with and without filler tube
   
„By way of example“, the filler hose of an „older model“ of gearbox is shown here. This hose is no longer used.
Nor is the „former“ filler neck with red hood necessary as the ATF can be drained and topped up through the lower hole. The „height“ of this rising hose determines the height of the ATF level.
To drain, remove the rising hose.
t  Following installation, check ATF level and top up → Chapter.
t  Filling amounts → Chapter .
O-rings, seals, gaskets and oil
t  Always install new O-rings, oil seals and gaskets.
t  After removing gaskets, check the contact surfaces of the casing and shaft for feathering or damage caused by the removal process.
t  Always replace paper gaskets, completely disposing of the used gasket and thoroughly cleaning the contact surfaces.
t  To fit the seal rings, smear them with ATF on the outer diameter and the seal lip.
t  Grease the O-rings with ATF before fitting so that they are not squashed during fitting.
t  No other lubricants may be used in the ATF area. Otherwise there is a danger of operation faults in the hydraulic gear mechanism.
t  The open side of the seals should face the liquid to be retained.
  N37-10325
t  Before fitting the radial gaskets, lubricate the space between the sealing rim using grease → Spare Spare parts catalogue
t  After fitting, check the ATF fluid level and top up if necessary
  Caution
Treat oil with care. Dispose of extracted oil with respect to the environment. Remember that one drop of oil can contaminate 1000 litres of drinking water.
Securing rings
t  Do not over expand the securing rings; replace them if necessary.
t  Securing rings must be well seated in the groove.
Bolts, nuts
t  The bolts are removed in reverse order to the tightening sequence.
t  The nuts and bolts for securing covers and casings, when not otherwise specified, must be removed is stages and diagonally.
t  Renew self-locking nuts.
t  The threads of those bolts fitted using a fixing agent must be cleaned using a wire brush. Next, insert the bolts with the fixing agent → Spare parts catalogue.
t  Specified torques given are for unlubricated nuts, bolts and screws.
t  Use a threaded connection to clean the remains of the fixing agent from all the threaded sockets in which the self-locking bolts are to go Otherwise, there is a risk of the bolts breaking when next removed
Electrical components
You are bound to have received an electric shock at some time on touching metal objects, caused by the electrostatic charge of the human body. This static charge may cause errors in the functioning of the electrical components in the gearbox and the gearbox operation mechanism if touched.
–  Therefore, we recommend touching any earthed object (for example, a waterpipe or lifting platform) before working with electronic components. Do not directly touch the contacts or electrical components which are „disconnected“.
Guided fault location, vehicle self-diagnosis and measurement module
  N32-0001
t  Before any repairs to the automatic gearbox, locate the cause of the fault as precisely as possible using the central diagnosis -VAS 505X- in operation mode„Guided fault finding“
  W00-10343
t  Diagnostics connection. Installation location: the diagnosis socket is located below the footwell cover, driver's side → Bodywork, interior fitting work; Rep. gr.68.
  E90-10021

Cleaning norms when working in the gearbox > < Instructions for tow starts and when towing