RKPP
1. When installing the manual transmission, make sure that the guide bushings fit correctly between the engine and the manual transmission.
2. When installing support brackets or waxed components, clean the mating surfaces of wax and grease.
Seals
3. After removing the gaskets and seals, always check the mating surfaces of the crankcase or shaft for any unevenness that may have occurred after removal.
4. Before installing radial seals (oil seals) half fill the space between the sealing lips with grease G052 128 A1 (see resist. illustration).
2.4 Area between the sealing lips of the stuffing box
5. The open side of the stuffing box must face the process fluid.
6. Lightly lubricate the O-rings before installation so as not to damage them during installation.
7. Thoroughly clean the split surfaces and apply sealant AMV 188 200 03 to them.
8. Apply sealants evenly and not too thick.
9. After replacing the seal, check and correct the fluid level (see chapter 1).
Fixing parts
10. Always replace retaining rings and do not overtighten.
11. Retaining rings must be located exactly in the grooves.
12. Always replace spring pins. Install them so that the slot is located along the line of action of the force.
Nuts and bolts
13. Loosen and tighten the threaded fasteners of covers and casings in a diagonal pattern.
14. Do not skew thin and fragile parts such as the clutch pressure plate; tighten their fasteners in several approaches in a diagonal order.
15. The specified tightening torques apply to unlubricated threaded fasteners.
16. Replace self-locking nuts and bolts. Because crankcase manual transmission is made of magnesium alloy, use fasteners, the use of which will not cause contact corrosion.
17. Remove any remaining thread locking compound from the threaded holes with a cleaning tool before driving the self-locking bolts into the holes. Otherwise, there is a risk of shearing the bolts when they are subsequently removed.
Clutch
18. Do not skew the pressure plate: loosen and tighten the fasteners in several approaches in a diagonal order.
19. If the clutch is burnt, thoroughly clean the clutch housing and flywheel friction surface with a cloth to reduce odor.
Bearings
20. Install new tapered roller bearings as supplied; do not apply additional lubricant.
21. Install needle bearings so that the side with the letters (thicker metal layer) facing the installation tool.
22. Tapered roller bearings mounted on a single shaft must be replaced as an assembly.
23. Before installation, heat the inner races of the bearings to approximately 100°C.
24. Do not interchange outer and inner races of bearings of the same size, as they are in pairs.
Synchronizers
25. Do not swap synchronizer rings. When reusing them, always install the same rings.
26. Replace worn synchronizers.
27. Check grooves (1 per resist. illustrations) gear rings (A) and inner rings for flat spots (worn grooves). Ring plating (in the presence of) should not be erased.
2.27 Checking the synchronizer
28. If an intermediate ring is installed (B in Figure 2.27), check its outer friction surface (2) and inner friction surface (3) for scoring, abnormal wear and discoloration due to overheating.
29. Check the timing gear cone for nicks and signs of abnormal wear.
30. Lubricate synchronizers with gear oil before installation.
Other Features
31. Use only suitable fasteners, do not allow the development of contact corrosion.
32. Before installing the gears, clean them and heat them up to no more than 100°C.
33. After installing the synchronized gears, check their smoothness.