Components

Components, 02M/02Y, 5 & 6 Speed M/T, AWD

Transmission
^ When installing manual transmission, make sure centering sleeves are correctly seated between engine and transmission.
^ Clean contact surfaces when repairing mounting brackets and waxed components. Contact surfaces must be completely free of oil and grease.
^ When replacing manual transmission/bevel gear transfer case, gear oil must be topped off.
^ Capacity and specification Code letters, assembly allocation, ratios, capacities.

O-rings, gaskets, seals
^ Always replace O-rings, gaskets and sealing rings.
^ After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal or for other signs of damage.
^ Always clean joint surfaces and apply sealant AMV 188 200 03.
^ Apply sealant evenly, do not apply too thick.

Before installing:





^ Lightly coat radial shaft oil seals outside circumference, fill space between sealing lips - arrow - halfway with sealing grease G 052 128 A1.
^ The open side of the oil seal faces toward the fluid to be sealed in.
^ When pressing in new seals, make sure sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

After installing:
^ Check gear oil level in manual transmission with bevel gear transfer case Gear oil in manual transmission with bevel gear transfer case.





Circlips
^ Do not over-stretch circlips.
^ Always replace damaged or over-stretched circlips.
^ Circlips must be fully seated in groove.
^ Replace roll pins. Position: Slot - A - is longitudinal to line of force - arrow -.

Nuts, bolts
^ Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.
^ Do not cant, and loosen and tighten especially sensitive parts - e.g. clutch pressure plates - in diagonal manner in stages.
^ The tightening torques specified apply to non-oiled nuts and bolts.
^ Always replace self-locking nuts and bolts.
^ For all hose connections, they must be checked that contact surfaces as well as bolts and nuts, if necessary, are to be waxed only after installation.

Bearings
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Lubricate all bearings (except tapered roller bearings) with gear oil when inserting into transmission.
^ Replace tapered roller bearings on one shaft together and use new bearings from same manufacturer.
^ Heat tapered roller bearing inner races to approx. 100°C before installing. Press in to stop so that there is no axial play.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the mandrel.

Shims
^ Measure shims at several points using a micrometer. Different tolerances make it possible to measure the required shim size exactly.
^ Check for burrs and signs of damage.
^ Only install perfect shims.

Synchronizer rings
^ Do not interchange. If reusing, allocate synchronizer rings to the same gear as before.
^ Check for signs of wear; replace if necessary.
^ Lubricate with gear oil before installing.

Gears
^ Before pressing on, clean and heat to approx. 100°C on a heater.
^ Temperature can be checked using temperature tester V.A.G 1558.

Sliding Gears
^ After assembling, check axial play of 1st to 6th sliding gears and check for free movement.

Clutch mechanism
^ Do not cant clutch pressure plate; loosen and tighten in a diagonal sequence and in stages.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission in order to reduce the smell of burnt linings.