Audi Workshop Service and Repair Manuals

General repair instructions Proper tools and the maximum possible care and cleanliness are essential for satisfactory repairs to the transmission units. The usual basic safety precautions also naturally apply when carrying out repair work. A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They apply to the work described in this Manual. Special tools t  For a complete list of special tools used in this Workshop Manual → Workshop equipment and special tools. Gearbox t  Allocate bolts and other components according to → Electronic parts catalogue. t  Clean contact surfaces when assembling mounting brackets and waxed components. The contact surfaces must be free of wax and grease. t  Thoroughly clean all joints and connections and the surrounding areas before dismantling. t  When installing the gearbox, ensure that the dowel sleeves between the engine and the gearbox are correctly located. t  For gear oil specification, refer to → Electronic parts catalogue. t  Gear oil must be filled up as required after repairing the gearbox.

Capacity (gearbox completely dismantled)	Capacity (gearbox partially dismantled) → Chapter
1.9 ltr.	1.7 ltr.

Sealants t  Thoroughly clean housing contact surfaces before applying sealing paste. t  Apply sealing paste -AMV 188 200 03- evenly and not too thick. t  Breather holes must remain free of sealing paste. Oil seals, seals, O-rings and gaskets t  Always renew oil seals, O-rings and gaskets. t  After removing gaskets and oil seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.

t  Before installing oil seals, lightly oil the outer circumference of the seal and fill the space between the sealing lips -arrow- about half full with grease -G 052 128 A1-. t  The open side of the oil seal should face the side containing the fluid. t  When installing a new oil seal, position the seal such that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth tolerances). t  Lightly lubricate O-rings with oil before installation to prevent them being trapped during assembly. t  Check oil level after installing new gaskets, O-rings and oil seals → Chapter. Locking elements

t  Do not over-stretch circlips. t  Installation position for some circlips: the circlip is fitted so that the narrow part of the gap is at the top. This also gives the pliers a better grip when removing and installing. t  Always renew circlips which have been damaged or over-stretched. t  Circlips must be properly seated in the base of the groove.

t  Renew spring pins. Position: the slit -A- should be in line with the line of force -arrow-.

Nuts, bolts t  Loosen the nuts and bolts in reverse sequence to the specified tightening sequence. t  Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified. t  Loosen and tighten particularly sensitive parts in diagonal sequence and in stages, taking care to keep them straight. t  Always renew self-locking nuts and bolts. t  The tightening torques stated apply to non-oiled nuts and bolts. t  Use a wire brush to clean the threads of bolts which are secured with locking fluid. Then apply locking fluid -AMV 185 101 A1- to bolt threads before installing. t  Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a thread tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed. t  For all threaded connections, ensure that (where applicable) the contact surfaces and the nuts and bolts are not coated with wax until after assembly is completed. Bearings t  Lubricate all bearings in gearbox housing with gear oil before installing. t  Use inductive heater -VAS 6414- to heat inner races of tapered roller bearings to approx. 100°C before installing. Press home onto stop when installing so there is no axial clearance. t  Do not interchange the outer or inner races of bearings of the same size (the bearings are paired). t  If required, renew the tapered roller bearings on one shaft together and use new bearings from a single manufacturer. t  Install needle bearings, ball sleeves and roller bearings so the lettering (side with thicker metal) faces towards the installing tool.

Shims t  Use a micrometer to measure the shims at several points. Tolerance variations make it possible to obtain the exact shim thickness required. t  Check for burrs and damage. t  Install only shims which are in perfect condition. Synchro-rings t  Do not interchange synchro-rings. When reusing always fit to the same selector gear. t  Check for wear; renew if necessary.

t  Check the grooves -arrow 1- on synchro-ring -A- and on inner ring for wear (flattened sections in grooves). t  Make sure that the coating of coated synchro-rings is not damaged. t  If an intermediate ring -B- is fitted, check the outer contact surface -arrow 2- and inner contact surface -arrow 3- of the intermediate ring for »scoring«, »visible traces of wear« and »blue discolouration (caused by overheating)«. t  Check chamfer on selector gear for scoring and visible traces of wear. t  Lubricate synchro rings with gear oil before installing. Gear wheels t  Clean before pressing on. t  Use inductive heater -VAS 6414- to heat to approx. 100°C before installing. Press home onto stop when installing so there is no axial clearance. t  Note correct installation position. Selector gears and locking collars t  After installing, check 1st to 5th selector gears for minimal axial play and freedom of movement.

t  Abnormal wear on synchro-ring or selector gear: A -  Worn chamfer on dog teeth of synchro-ring or selector gear.

t  In comparison: intact synchro-ring or selector gear: B -  Intact chamfer on dog teeth of synchro-ring or selector gear.

t  Abnormal wear on locking collar: C -  Worn chamfer on internal splines of locking collar.

t  In comparison: intact locking collar: D -  Intact chamfer on internal splines of locking collar. Clutch actuation t  When removing gearbox, remove clutch slave cylinder without disconnecting pipes. t  Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic pipe is still connected. Otherwise the piston will be pressed out of the clutch slave cylinder. t  If the clutch pedal does not return to its initial position after releasing it (clutch pedal in rest position), you must bleed the clutch system (further measures → Chapter „Notes on removing and installing clutch master cylinder and slave cylinder“). t  Keep clutch pressure plate straight when removing and installing t  If the clutch has burnt out, thoroughly clean the clutch housing, flywheel and parts of the engine facing the gearbox in order to prevent odour. t  Only blow out dual-mass flywheel with compressed air.