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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, naturally 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
For a complete list of special tools used in this
Repair Manual
Special Tools Catalog
Transmission
When installing a replacement transmission or
rear final drive, check oil level and top-up if
necessary Page 34
-39
and Page 39
-80
.
Vehicles with 2.7 ltr 195 kW engine:
replacement transmissions contain an
additional 0.3 ltr of oil for the lines of the
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Thoroughly clean all connections and the
surrounding area before disconnecting.
When installing transmission, ensure dowel
sleeves are correctly seated.
O-rings, seals, gaskets
Always replace O-rings, seals and gaskets.
After removing gaskets and seals, always
inspect the contact surface 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 oil seals, lightly oil outer edge and fill
space between sealing lips (arrow) with a thin coating of sealing
grease G 052 128 A1. The open side of the oil seals faces toward the side with fluid filling.When replacing oil seals, always vary the point at which the sealing
lips make contact (use insertion depth tolerances). Lightly oil O-rings before installing; this prevents the rings being
crushed when inserting. Check oil level after replacing gaskets and oil seals Page 34
-39
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Synchronizer rings
Do not interchange synchronizer rings. When
reusing always fit to the same gear.
Check for wear, replace if necessary.
Lubricate with gear oil before installing.
Clutch mechanism
When removing transmission, remove clutch
slave cylinder without disconnecting lines.
If the slave cylinder is removed with the
hydraulic line attached, do not depress clutch
pedal. Otherwise the piston will be pressed out
of the slave cylinder.
Ensure that the pressure plate is kept straight:
loosen and tighten bolts in a diagonal sequence
and in several gradual stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the clutch bellhousing, the
flywheel and the parts of the engine facing the
transmission.
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