General Repair Instructions

General repair instructions
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when performing vehicle repairs.

Special tools
A summary of the special tools used in the repair manual can be found in the Library under "Special Tools".

Transmission
^ When an automatic transmission is replaced the following fluid levels must be checked:
- ATF in planetary gearbox and final drive.
- Capacities and specifications; Refer to Automatic Transaxle, Specifications, Capacities
^ Do not run engine or tow vehicle with oil pan removed or when there is no ATF in transmission.
^ Secure torque converter against falling out when transmission is removed.
^ Clean joints and connecting points thoroughly before loosening.
^ When installing the transmission ensure that the dowel sleeves between the engine and the transmission are seated correctly.
^ Place parts that have been removed on a clean surface and cover so that they are not soiled. Use foil and paper. Do not use fluffy cloths!
^ Only install clean components: Only unpack replacement parts immediately prior to installation.
^ Carefully cover opened components or seal if the repair cannot be performed immediately.
^ Replace transmission if any of the selector elements are scorched/burned.
^ A basic (default) setting must be performed each time the transmission is reinstalled.

Gaskets, seals
^ Always replace O-rings, seals and gaskets.
^ After removing seals/gaskets etc. always check contact surfaces on housings or shafts for burrs and damage and correct before reinstalling.
^ The open side of an oil seal faces toward the oil.
^ Before installing an oil seal moisten the outer surfaces and the sealing lip sparingly with ATF.
^ Moisten O-rings with ATF to prevent damage to the O-ring when installing.
^ Only use ATF in the areas normally lubricated by ATF. Other lubricants will cause the hydraulic elements to malfunction.
^ After installing, check ATF level in planetary gearbox/final drive and correct levels as necessary.
- ATF in planetary gearbox and final drive.
Bolts, nuts
^ Loosen and tighten the screws and bolts for securing the covers and housings in a diagonal sequence.
^ Do not cant particularly sensitive parts, e.g. valve body, and loosen and tighten in stages using diagonal sequence.
^ Prescribed torque specifications apply to unoiled nuts, screws/bolts.
^ Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert bolts/screws with AMV 185 100 A1.
^ All threaded holes where locking fluid is employed must be cleaned with a thread tap to remove remnants of locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.
^ Replace self locking nuts and bolts/screws.

Valve body
^ The valve body is allocated according to transmission code, parts catalog.

Guided fault finding, vehicle self-diagnosis and measuring technology





^ Before servicing the automatic transmission, determine the cause of the malfunction as precisely as possible with Vehicle Diagnosis, Test and Information System VAS 5051 with the aid of "Guided fault finding", "Vehicle self-diagnosis" and "Measuring technology".