Components

Components

Transmission

• Make sure that the alignment sleeves between the engine and transmission are positioned correctly when installing the transmission.

• Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.

• For the correct bolt allocation, refer to the Parts Catalog.

• Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

• For the correct capacity and fluid specification, refer to Fluid Capacity Tables.

Sealant

• Clean the housing separating surfaces thoroughly before applying the sealant.

• Apply the sealing paste (AMV 188 200 03) evenly and not too thick.

Gaskets, Seals and O-rings

• Replace the gaskets, seals and O-rings

• After removing the gaskets and seals, always inspect the contact surfaces on the housings or shafts for burrs resulting from removal, or for other signs of damage.

• Before installing the seals, lightly oil the outer circumference and fill the space between the sealing lips - arrow - halfway with sealing grease for seal (G 052 128 A1).






• The open side of the seal points toward the fluid to be sealed in.

• Press in new the seal, so that the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

• Lightly lubricate O-rings before installing them in order to prevent them from being crushed when inserting.

• After replacing the seals and O-rings, check the transmission fluid level and fill as necessary. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

Fasteners

• Do not overstretch the circlip.






• Installed position for some of the circlips: The circlip is narrower on top and this shape matches its installed location. This makes it easier for the pliers to grab the circlip when removing and installing it.

• Always replace damaged or stretched circlips.

• The circlips must fit completely inside the groove.

• Replace the roll pins. Installed position: The slit - A - should be in line with the line of force - arrow -.






Bolts and Nuts






• Loosen the bolts and nuts opposite the tightening sequence.

• Bolts and nuts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.

• Especially delicate parts, such as a clutch pressure plate, must not be distorted. Loosen and tighten the bolts and nuts in stages and in a diagonal sequence.

• The tightening specification stated apply to non-lubricated nuts and bolts.

• Always replace self locking nuts and bolts.

• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.

• Use a wire brush to clean the threads of bolts that were installed using liquid locking fluid. Next, use liquid locking fluid (AMV 185 101 A1) to install the bolts.

• Clean the threaded holes for the self-locking bolts or for the bolts coated with the locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.

Bearings

• Insert all bearings in the transmission housing using transmission fluid.

• Heat the tapered roller bearing inner races to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Press on until seated when installing, so there is no axial clearance.

• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.

• Set the needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward the drift.

Adjusting Shims






• Measure the adjusting shims at several locations with a micrometer caliper. Tolerance variations make it possible to find the exact shim thickness required.

• Check for burrs and damage.

• Only install perfect shims.

Synchronizer Rings

• Do not interchange them. When reusing synchronizer rings, always install them to the same gear.

• Check for wear and replace as necessary.

• Check the grooves - arrow 1 - on the synchronizer ring - A - and the inner race for flat areas (grooves are worn).






• The coating on the synchronizer rings must not be damaged.

• If an intermediate ring - B - is installed, check the outer friction surface - arrow 2 - and the inner friction surface - arrow 3 - for grooves and scoring.

• Check the taper of the drive gear for grooves and scoring.

• Coat the synchronizer ring with transmission fluid and then install.

Toothed Gears, Synchronizer Hubs

• Heat the synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Press on until seated when installing so there is no axial play.

• Pay attention to the installed position.

Selector Gears

• After assembling, check the selector gears for minimum axial clearance and ease of movement.

Clutch

• Do not tilt the clutch pressure plate. Loosen and tighten it diagonally and in small steps.

• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing and the flywheel running surface with a clean cloth.