General Repair Information
General Repair Information
Transmission Construction and Function
More information about the construction and function can be found in 89K303Six-Speed Automatic Transmission 09D.
Tools
A list of special tools and workshop equipment required for repair procedures in this manual can be found at the start of each repair procedure and in the "Special Tools" catalog.
With small fasteners with minimal tightening specifications, uncertainties often exist. Torque wrench 5-60 Nm (V.A.G 1783) can be used for these fasteners.
Transmission
• If covers are removed from the transmission or the transmission is without fluid, do not run the engine and do not tow the vehicle.
• Always clean connection points and the vicinity first and then loosen.
• When installing the transmission, make sure the alignment pins are correctly installed between the engine and transmission.
• Place removed parts on a clean surface and cover them so they do not become contaminated. Use foil or paper. Use lint free cloths only!
• Carefully cover or seal unpacked components if repairs cannot be performed immediately.
• Only install clean components: Install replacement parts immediately after removing them from their packaging.
• Do not run the engine or tow the vehicle with the oil pan removed or when there is no Automatic Transmission Fluid (ATF) in the transmission.
• Secure the torque converter on a removed transmission to keep it from falling out.
• Check the ATF level after installing. Refer to => [ Automatic Transmission Fluid Level, Checking and Filling ] Automatic Transmission Fluid Level, Checking and Filling.
O-rings, Gaskets and Seals
• Always replace O-rings, gaskets and seals.
• Once a seal or gasket has been removed, check the contact surface on the housing or shaft for burrs and damage. Repair as necessary.
• Before installing a seal, lightly lubricate the outer circumference and sealing lip with ATF, depending on the component location.
• Only use ATF for automatic transmission components. Other lubricating substances cause functional problems in the hydraulic transmission control.
• The open side of the seal face toward the oil.
• Check the ATF level after installing. Refer to => [ Automatic Transmission Fluid Level, Checking and Filling ] Automatic Transmission Fluid Level, Checking and Filling.
Automatic Transmission Fluid
CAUTION!
Be cautious when dealing with transmission fluid. Dispose of the drained fluid properly. Remember: one drop of transmission fluid can contaminate 1,000 liters of drinking water.
Do not mix any additives with the fluid, and do not add other fluids.
Drained fluid must not be used to fill again.
ATF is obtainable as a replacement part.
Container size 1.0 L - replacement part no. (G 055 025 A2)
Bolts and Nuts
• Loosen and tighten bolts or nuts for securing covers and housings in a diagonal sequence.
• The tightening specification stated applies to non-lubricated nuts and bolts.
• Clean the threads of bolts that were applied with locking fluid using a wire brush. Apply locking fluid (AMV 185 101 A1) before reinstalling.
• All threaded bores in which self locking bolts are threaded must be cleaned of remaining locking fluid using a tap. Otherwise there is a risk that the bolts will shear the next time they are removed.
• Replace self locking bolts and nuts.
Electrical Components
You have probably received a electrical shock at one time, when touching a metal item. The reason for this is the electrostatic charge that is built up in the human body. This charge can lead to malfunctions when contacting the electrical components of the transmission and the gear selector.
- Touch a grounded object, for example, a water pipe or a hoist, before working on electrical components! Do not make direct contact with connector contacts.
Guided Fault Finding, On Board Diagnostics and Test Instruments
Before performing work on the transmission, the cause of damage must be determined as exactly as possible via "Guided Fault Finding".
Guided Fault Finding is performed using the vehicle diagnosis, testing and information system (VAS 5051).