| To carry out gearbox repairs successfully and correctly, scrupulous care and cleanliness, as well as the proper tools, are essential requirements. Obviously, the generally valid basic safety rules apply to repair work. |
| A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here. They apply to this workshop manual. |
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| Do not run the engine or tow the vehicle when the oil pan has been removed or without filling with ATF. |
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| When replacing the automatic gearbox, check the ATF in the planetary gear → Chapter and the ATF on the final drive side → Chapter if necessary top up. Capacities and specification → Chapter. |
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| Secure the torque converter against dropping out when the gearbox is removed. |
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| Thoroughly clean the connection points and their surroundings before releasing. |
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| Before installing the gearbox check the fitting dimension of the torque converter → Chapter. |
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| When installing pay attention to the correct position of the dowel sleeves. |
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| Place removed parts on a clean surface and cover. Use foil and paper. Do not use fuzzy cloths! |
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| Carefully cover or close opened components if the repair is not completed immediately. |
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| Only install clean parts: Remove spare parts from their wrapping immediately before installing. |
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| Regulations concerning cleanliness when working on the automatic gearbox → Chapter. |
| O-rings, gasket rings, gaskets |
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| Always replace O-rings, gasket rings and gaskets. |
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| After removing gaskets, check the contact surface in the housing or shaft for burrs or damage which occured during the disassembly. |
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| Before installing the gasket rings coat the outer circumference and sealing lip with ATF. |
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| Before inserting the O-rings coat with ATF to prevent the rings being squashed during installation. |
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| Never use other lubricants in the ATF area. Otherwise there is the risk of the gearbox hydraulic control system to malfunction. |
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| The open side of the sealing rings is turned towards the fluid to be sealed. |
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| After installation check ATF level in the planetary gear and gear oil level in the final drive, correct if necessary. |
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| Do not over-tension the circlips. |
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| Replace damaged or over-tensioned circlips. |
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| Slacken the bolts against the tightening sequence. |
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| Slacken and tighten nuts and bolts for attaching covers and housings without tightening sequence diagonally across in stages. |
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| Particularly sensitive components -such as the slide valve body must not be tilted- loosen and tighten crosswise, by stages. |
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| Always replace self-locking nuts. |
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| Clean the thread of the screws that are inserted with a locking agent with a wire brush. Insert bolts with locking agent -AMV 185 101 A1-. |
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| Clean all threaded holes into which self-locking screws are screwed in, using a screw-tap to remove locking agent residues. Otherwise there is a risk that the bolts will shear at the next disassembling. |
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| Tightening torques apply for non-oiled nuts and bolts. |
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| Position needle bearing with the lettered side (thicker end) towards the drift pin. |
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| Depending on the fitting location, insert the bearing with axle oil or ATF. |
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| Tapered-roller bearings are arranged in the spare parts catalogue according to gearbox manufacturing date and identification characters. |
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| Do not mix up the outer and inner races of bearings of the same size. |
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| Always jointly replace tapered-roller bearings on the same shaft and use products of the same manufacturer. |
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| Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely. |
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| Inspect for burrs and damage. Install only shims which are in perfect condition. |
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