General Notes on Repairing

General notes on repairing, 09G, 6 Spd. A/T
To repair the transmission perfectly and successfully always use the greatest care and levels of cleanliness. The tools also have to be in perfect condition. Naturally, the general safety rules apply.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points; are summarized here.

Transmission
^ When an automatic transmission is exchanged check the following fluid levels:
- Fill level and specification
- ATF in planetary gearbox and final drive

^ Do not run the engine or tow the vehicle with the oil pan removed or when there is no ATF in the transmission.
^ Secure the torque converter to prevent it falling out when the transmission is removed.
^ Clean the joint areas 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 them 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 them if repairs cannot be performed immediately.
^ Replace the transmission if any of the selector elements are scorched/burned.
^ Perform a basic (default) setting 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 repair 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 that call for ATF. Other lubricants will cause the hydraulic elements to malfunction.
^ After installing, check the ATF level in the planetary gearbox/final drive and correct the levels as necessary.
- Filling level and specification
- ATF in planetary gearbox and final drive

Bolts, nuts
^ Loosen and tighten the nuts, bolts/screws 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 a diagonal sequence.
^ The tightening torques indicated refer to non-lubricated screws and bolts.
^ Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert the bolts/screws with AMV 185 100 A1.
^ Clean all threaded holes where locking fluid is employed 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.

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 the Vehicle diagnosis, testing and information system VAS5051 with the aid of "Guided fault finding", "Vehicle self-diagnosis" and "measuring technology".