Repair Instructions

Repair Instructions

For the transmission to be repaired successfully and to function correctly, the greatest possible care and cleanliness and proper tools are required. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A series of generally applicable notes for individual repair procedures have been gathered here which otherwise would be listed several times in many places in the repair manual. They apply to this Repair Manual.

Guided Fault Finding, On Board Diagnostic (OBD) and measuring technology

• Before performing repairs on the transmission, the cause of the malfunction must be determined as accurately as possible in the operating modes guided fault finding, vehicle on-board diagnosis and test instruments.

Transmission

• Do not run engine or tow vehicle with oil pan removed or without transmission fluid.

• When replacing the transmission, check and top off gear oil. Refer to => [ Gear Oil Level, Checking and Filling ] Gear Oil Level, Checking and Filling; capacities => [ Capacities ] Automatically Shifted Manual Transmission/Transaxle, specification. Refer to the electronic parts catalog ETKA.

• Make sure alignment bushings are properly installed during installation.

Seals, O-rings, shaft seals

• Replace seals, O-rings, shaft seals

• After removing seals, check sealing surfaces on housing or shaft for burrs resulting from removal or damage.

• Replace seals, completely remove old seal and clean sealing surfaces.

• Coat O-rings with gear oil before inserting to prevent crushing rings during installation.

• Lightly oil outer diameter of radial shaft seals and fill space between sealing lips - arrow - halfway with sealing grease, sealing grease. Refer to the electronic parts catalog ETKA.





• Do not use any other lubricants in gear oil area. Otherwise, there is a risk that the hydraulic transmission controls could malfunction.

• The open side of the shaft seals point toward the fluid to be sealed in.

• Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• After installing, check transmission oil level and top off. Refer to => [ Gear Oil Level, Checking and Filling ] Gear Oil Level, Checking and Filling.

Locking elements

• Do not strain circlips (replace if necessary).

• Circlips must be properly seated in base of groove.

Bolts and nuts

• Loosen bolts in reverse order of tightening.

• Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.

• Replace self-locking nuts.

• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with locking compound; locking compound. Refer to the electronic parts catalog ETKA.

• The tightening torques stated apply to unoiled bolts and nuts.

• Tightening torque with additional torque: After tightening to torque, these bolts must be tightened further to the specified angle, for example 40 Nm plus an additional 90° (90° corresponds to a quarter turn).