General repair instructions Page 1 of 10

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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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Thoroughly clean all connections and the

surrounding area before disconnecting.

When installing transmission, make sure

centering sleeves for aligning engine and
transmission are correctly seated.

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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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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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Circlips

Do not over-stretch circlips.

Always replace.

Circlips must be fully seated in groove.

Always replace roll pins.

Installed position: slot -A- is longitudinal to line of force (arrow).

Nuts, bolts

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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Bearings

Install needle bearings with the lettering on the

bearing (the side with thicker metal) facing the
drift.

Mark needle bearings of drive gears for first

through fifth sliding gears when removing to
ensure the same installed position when
installing.

Grease needle bearing for input shaft in

flywheel.

Lubricate all bearings in transmission with

transmission fluid before installing.

Heat tapered roller bearing inner races to

approx. 100 C (212 F) before installing. Press
in to stop so that there is no axial play.

Do not interchange inner and outer bearing

races with those from other bearings of the
same size.

Always replace tapered roller bearings on one

shaft together and use new bearings from the
same manufacturer.

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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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Shims

Use a micrometer to measure the shims at

several points. Different tolerances make it
possible to obtain the exact shim thickness
required.

Check for burrs and signs of damage.

Sliding Gears

After assembling, check axial play of 1st to 5th

sliding gears (0.15-0.35 mm) and check for free
movement.

Synchronizer rings

Do not interchange. When re-using, install

synchronizer rings with the same gear with
which they were matched.

Check for signs of wear; replace if necessary.

Lubricate with transmission fluid before

installing.

Gears, synchro-hubs, inner races for sliding

gears

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Heat gears and synchro-hubs to approx. 100

C (212 F) before installing. Press into stop so
there is no axial play.

Heat inner races for sliding gears to approx.

100 C (212 F) before installing.

The temperature can be checked using

VAG1558 temperature tester.

Note installation position.

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Clutch mechanism

When removing transmission, remove clutch

slave cylinder without disconnecting lines.

Do not depress the clutch pedal after removing

the slave cylinder if the hydraulic line is still
connected. Otherwise the piston will be pressed
out of the slave cylinder.

Do not cant clutch pressure plate; loosen and

tighten in a diagonal sequence and in stages.

If the clutch has burnt out, thoroughly clean the

bellhousing, flywheel and parts of the engine
facing the transmission in order to reduce the
smell of burnt linings.

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