| General repair instructions |
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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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| Install only clean parts: only remove replacement parts from packaging immediately prior to installation. |
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| After installation, check fluid level and fill up if necessary: ATF in planetary gearbox → Chapter or gear oil in final drive → Chapter. Filling amounts and oil type specifications → Chapter. |
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| O-rings, flanges and gaskets should always be replaced. |
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| After removing gaskets, check the contact surfaces of the casing and shaft for feathering or damage caused by the removal process. |
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| Thoroughly clean housing joint surfaces before assembling. |
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| Lightly lubricate the outer circumference and sealing lip of seals with ATF before installing. |
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| Grease the O-rings with ATF before fitting so that they are not squashed during fitting. |
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| In general, only ATF should be used in the ATF areas. Other lubricants will cause malfunction of the gearbox hydraulics. |
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| The open side of the seals should face the liquid to be retained. |
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| When installing a new oil seal, position the seal in the housing so 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 installation, check fluid level and fill up if necessary: ATF in planetary gearbox → Chapter or gear oil in final drive → Chapter. Filling amounts and oil type specifications → Chapter. |
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| The bolts are removed in reverse order to the 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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| If no tightening sequence is specified, nuts and bolts used to fix covers and casings should be tightened and loosened in stages and in diagonal pairs. |
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| Specified torques given are for unlubricated nuts, bolts and screws. |
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| Always renew self-locking nuts and bolts. |
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| The thread of bolts threaded with a fixing agent should be cleaned using a wire brush. Then insert the screws with the fixing fluid: Allocation → Spare parts catalogue. |
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| Threaded holes where there had been self-locking bolts or bolts with thread fixing agent must first be cleaned (for example, with a threading male). Otherwise there is a danger of the bolts shearing off the next time they are removed. |
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| Do not overstretch retaining rings. |
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| Always replace damaged or over-expanded safety rings. |
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| Securing rings must be well seated in the groove. |
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| Install needle bearings with lettered side (thicker metal) towards fitting tool. |
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| Lubricate bearings with gear oil or ATF, depending on fitting location. |
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| Do not confuse the outside and inside rings of the bearing with the rings from other bearings of the same size. |
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| If required, renew the tapered roller bearings on one shaft together and use new bearings from a single manufacturer. |
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| Measure shims at several points with a micrometer. The existence of different tolerances allows the necessary shim thickness to be selected exactly. |
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| Check that there are no burs or damage. Only fit shims in perfect state. |
| Guided fault finding must always be performed using the Vehicle diagnosis, testing and information system -VAS 505X- before commencing with any assembly work. |
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