1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of the Remco Automatic Transmission Overhaul Kit. This kit is designed for A4AF3, A4BF2, and A4BF3 automatic transmissions manufactured between 2000 and 2003. Please read this manual thoroughly before beginning any work to ensure proper installation and to prevent damage to the transmission or injury.
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2. Safety Information
Always prioritize safety when working with automotive components. Failure to follow safety precautions can result in serious injury or damage to property.
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Ensure the vehicle is securely supported on jack stands before working underneath it.
- Disconnect the vehicle's battery before performing any electrical work.
- Allow the transmission and engine to cool completely before servicing.
- Dispose of old transmission fluid and components responsibly according to local regulations.
- If you are unsure about any step, consult a qualified automotive technician.
3. Kit Contents
The Remco Automatic Transmission Overhaul Kit includes a comprehensive set of gaskets, seals, and other components necessary for a complete transmission rebuild. Please verify all components are present and undamaged upon receipt.
Figure 1: Overview of the Remco Automatic Transmission Overhaul Kit components. This image displays various gaskets, O-rings, seals, and valve body separator plates included in the kit, neatly arranged on a white surface. The components are designed for a complete transmission rebuild.
Typical components include:
- Gasket Set (pan gasket, valve body gaskets, etc.)
- Sealing Rings
- O-Rings
- Rubber Lip Seals
- Metal Clad Seals
- Friction Plates (not explicitly shown but common in overhaul kits)
- Steel Plates (not explicitly shown but common in overhaul kits)
- Filter (not explicitly shown but common in overhaul kits)
Refer to the specific parts list provided with your kit for exact contents.
4. Setup and Preparation
Proper preparation is crucial for a successful transmission overhaul. Ensure you have all necessary tools and a clean workspace.
4.1 Required Tools and Materials
- Standard Mechanic's Tool Set (sockets, wrenches, screwdrivers)
- Torque Wrench
- Transmission Jack or Engine Hoist
- Drain Pan for Transmission Fluid
- Cleaning Solvents (e.g., brake cleaner, parts cleaner)
- Shop Rags and Lint-Free Cloths
- New Transmission Fluid (refer to vehicle manufacturer specifications)
- Assembly Lube or Petroleum Jelly
- Service Manual for your specific vehicle model (highly recommended)
4.2 Workspace Preparation
- Ensure a clean, well-lit, and organized work area.
- Have a sturdy workbench for disassembling and reassembling transmission components.
- Prepare containers for organizing small parts and fasteners.
5. Overhaul Procedure (Installation)
This section outlines the general steps for overhauling an automatic transmission using the Remco kit. Always refer to your vehicle's specific service manual for detailed, model-specific instructions and torque specifications.
5.1 Transmission Removal
- Safely lift and support the vehicle.
- Drain the transmission fluid.
- Disconnect all electrical connectors, shift linkages, and cooler lines.
- Remove the driveshaft (RWD) or axles (FWD).
- Support the engine and remove transmission mounting bolts.
- Carefully lower and remove the transmission from the vehicle.
5.2 Disassembly and Inspection
- Place the transmission on a clean workbench.
- Disassemble the transmission components systematically, keeping track of all parts and their orientation. Use a service manual as a guide.
- Inspect all hard parts (gears, shafts, drums, valve body) for wear, damage, or scoring. Replace any damaged hard parts as necessary (these are not included in the overhaul kit).
- Clean all components thoroughly with appropriate cleaning solvents.
5.3 Component Replacement and Reassembly
- Replace all gaskets, seals, and O-rings with the new components from the Remco overhaul kit.
- Lubricate new seals and O-rings with assembly lube or clean transmission fluid before installation to prevent damage.
- Carefully reassemble the transmission, ensuring all components are correctly seated and aligned.
- Pay close attention to torque specifications for all fasteners, especially valve body bolts and case bolts. Refer to your vehicle's service manual.
5.4 Transmission Reinstallation
- Carefully lift and align the transmission back into the vehicle.
- Secure all transmission mounting bolts to the specified torque.
- Reconnect driveshaft/axles, cooler lines, electrical connectors, and shift linkages.
- Refill the transmission with the correct type and amount of new transmission fluid.
- Perform initial fluid level checks and adjustments.
6. Post-Overhaul Maintenance and Break-in
After completing the overhaul, proper break-in and ongoing maintenance are essential for the longevity of your transmission.
6.1 Initial Start-up and Fluid Level Check
- Start the engine and allow it to warm up.
- Cycle through all gear positions (P, R, N, D, L) while holding the brake, pausing briefly in each.
- Recheck the transmission fluid level on a level surface with the engine running and at operating temperature. Add fluid as necessary.
- Inspect for any leaks around the transmission case and cooler lines.
6.2 Break-in Period
Drive the vehicle gently for the first 500-1000 miles after an overhaul. Avoid heavy acceleration, towing, or aggressive driving during this period to allow new components to seat properly.
6.3 Regular Maintenance
- Follow your vehicle manufacturer's recommended schedule for transmission fluid and filter changes.
- Regularly check transmission fluid levels and condition.
- Address any unusual noises, shifting issues, or leaks promptly.
7. Troubleshooting
This section provides general guidance for common issues that may arise after a transmission overhaul. For complex problems, consult a professional technician.
| Problem | Possible Cause | Solution |
|---|---|---|
| Fluid Leaks | Improperly seated gaskets/seals, damaged seals during installation, loose pan bolts. | Inspect all sealing surfaces. Retorque pan bolts. Replace faulty seals or gaskets. |
| Harsh Shifting / Delayed Engagement | Low fluid level, incorrect fluid type, valve body issues, electrical sensor problems. | Check fluid level and type. Verify electrical connections. Consult service manual for valve body diagnostics. |
| No Engagement in Gear | Extremely low fluid level, internal mechanical failure, torque converter issue. | Check fluid level. If fluid is correct, professional diagnosis is required. |
| Overheating | Low fluid level, clogged cooler lines, internal friction, faulty cooler. | Check fluid level. Inspect cooler lines for obstructions. Test transmission cooler. |
8. Product Specifications
- Brand: Remco
- Manufacturer: Precision International
- Compatible Transmission Models: A4AF3, A4BF2, A4BF3
- Compatible Model Years: 2000-2003
- Item Weight: Approximately 1 pound
- Product Dimensions: Approximately 16 x 16 x 2 inches (packaging)
- ASIN: B0D1J8VGQG
Note: Always refer to your vehicle's specific service manual for precise fluid capacities, torque specifications, and detailed component diagrams.
9. Warranty and Support
For information regarding warranty coverage for your Remco Automatic Transmission Overhaul Kit, please refer to the documentation included with your purchase or contact Remco customer support directly. Support contact information can typically be found on the manufacturer's website or through your point of purchase.
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