Repair Instructions

Repair instructions, 02E, 6 Speed Direct Shift A/T, AWD
Proper tools and the maximum possible care and cleanliness are essential for successful transmission repairs. The usual basic safety precautions also naturally apply when performing vehicle repairs.

A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the Repair Manual - are summarized here. They apply to the work described in this Manual.

Guided fault finding, vehicle self-diagnosis and testing system





^ Before servicing the transmission, the exact cause of the failure must be determined as precisely as possible via the vehicle diagnostic, testing and information system VAS5051 in the modes "Guided Fault Finding", "vehicle self-diagnosis" and "testing system".

Special tools
For a compilation of the special tools used in this Workshop Manual refer to "Special tools" and "Workshop equipment".

Transmission
^ Do not run the engine or tow the vehicle with the oil pan removed or when there is no gear oil in the transmission.
^ When replacing the transmission the gear oil must be checked and topped up, if necessary. Filling quantities and specification see Capacities.
^ Thoroughly clean all joints and surrounding areas before disassembling.
^ When installing the transmission, ensure that the dowel sleeves are fitted correctly.

O-rings, oil seals, gaskets
^ Always install new O-rings, oil 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.
^ Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly.
^ Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing.
^ Lightly lubricate O-rings with gear oil or Vaseline before inserting to prevent them from getting crushed during assembly.
^ Do not use any other lubricants where gear oil is used. Otherwise, there is a risk of problems occurring in the transmission hydraulics.
^ The open side of the oil seals faces the side with fluid filling.
^ Observe the rules for cleanliness.
^ After installing, check the gear oil level, adjust to correct level if necessary.

Locking elements
^ Do not overstretch locking rings/circlips; replace if necessary.
^ Locking rings/circlips must be properly seated in the base of the groove.

Nuts, bolts
^ Loosen bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be loosened and tightened in a diagonal sequence and in stages if no tightening sequence is specified.
^ Replace self-locking nuts.
^ Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply AMV 185 101 A1 when inserting.
^ The tightening torques stated apply to non-oiled nuts and bolts.