General Repair Instructions

Repair Instructions Summary
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions for servicing vehicles also apply when working on the transmission.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the repair instructions, are summarized here. They apply to these repair instructions.

Special Tools
A summary of the special tools used in this Repair Manual can be found in Special tools/Workshop equipment catalogs.

Transmission
When an automatic transmission is exchanged, the VW ATF in the planetary gearbox, and the gear oil in the final drive, is to be checked and topped up as necessary.

When installing the transmission, ensure that the dowel sleeves are correctly installed.

Gaskets, Oil Seals
Radial shaft seals: Pack space between sealing lips with grease -arrow- before installing.

Always install new O-rings.

After installing check ATF level in tHE drive or planetary gearbox, adjust to correct level if necessary.

Locking Elements
Do not overstretch circlips; replace if necessary.

Circlips must be properly seated in grooves.

Nuts, Bolts
Nuts and bolts for attaching covers and housings must be loosened and tightened in a crosswise pattern.

Do not distort particularly sensitive parts, e.g. valve body, and loosen or tighten diagonally in stages.

The tightening torques stated apply to unoiled nuts and bolts.

Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Then install bolts with AMV 185 100 Al.

Always replace self-locking nuts.

Bearings
Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.

Lubricate all bearings in the transmission with gear oil before installing. Oil with special care for measuring friction torque.

Heat the inner races of taper roller bearings to approx. 100°C (212°F) before installing.

Do not interchange the inner and outer races of same size bearings.

Always replace tapered roller bearings which are mounted on a shaft together and only use bearings from a single manufacturer.

Shims
Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.

Check for signs of burrs and damage. Only install shims which are in perfect condition.


Inner Plates
Place new inner plates in ATF fluid for 15 minutes before installing.

Valve Body
Replace the valve body if any of the selector elements are scorched.

Clutches
Clutches K1, K2 and K3 should initially be disassembled only for cleaning. If parts are faulty, replace clutch. Application of the clutches is by the transmission code letters.