Page 1 of 10
00-10
General repair instructions
The maximum possible care, cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also apply when
carrying out vehicle repairs.
A number of generally applicable instructions for
individual repair operations, which are otherwise
mentioned at various points in the Repair
Manual, are summarized here. They apply to this
Repair Manual.
Special tools and equipment
For a complete list of special tools and
equipment used in this repair manual "Special
tools catalog."
Transmission
Using parts catalog microfiche, match bolts and
other components according to transmission
codes Page 00
-3 .
After replacing the manual transmission , check
oil level and top-up if necessary Page 34
-36
.
Capacities and specifications Page 00
-3 .
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Page 3 of 10
00-11
Sealants
Thoroughly clean housing joint surfaces before
applying sealant.
Apply sealant AMV 188 000 02 or AMV 188 001
02 evenly and not too thick.
Breather holes must be free of sealant.
O-rings, gaskets, seals
Always replace O-rings, gaskets and seals.
After removing gaskets and seals, always
inspect the contact surfaces on the housing or
shaft for burrs resulting from removal, or for
other signs of damage.
Thoroughly clean housing joint surfaces before
assembling.
Before installing radial shaft seals, lightly oil outer edge and fill space
between sealing lip and dust lip (arrow) with oil. Open side of the seal faces toward the side containing the oil.When replacing seals, always vary the point at which the sealing lips
make contact (use insertion depth tolerances).
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Page 4 of 10
Lightly lubricate O-rings before installing. This prevents the rings from
being pinched while being inserted. Check transmission oil level after replacing gaskets and seals Page 34
-36
.
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Page 5 of 10
00-12
Circlips
Do not over-stretch circlips.
Always replace.
Circlips must be fully seated in groove.
Nuts, bolts
Always replace roll pins. Installed position: slot -A- is longitudinal to line of force (arrow).Always replace self-locking nuts and bolts.Loosen nuts or bolts opposite to torque sequence.Tighten and loosen bolts or nuts for securing covers and housings in a
diagonal sequence. The tightening torques stated apply to non-oiled nuts and bolts.The threads of bolts which are secured by a locking compound should
be cleaned using a wire brush. Then apply AMV 185 101 A1 when
installing. Threaded holes for self-locking bolts or bolts coated with locking fluid
must be cleaned with tap. Otherwise there is a danger of bolts
shearing when subsequently being removed.
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Page 7 of 10
The tapered roller bearings for the output shaft
and the differential in the manual transmission
are low-friction bearings. Do not additionally oil
new tapered roller bearings when measuring
friction torque. The bearings are pre-treated at
the factory with a special type of oil for this
purpose.
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