Audi Workshop Service and Repair Manuals

→ There are two types of gearboxes:

•     A -    Gearboxes with a corrugated spring washer fitted on the last outer plate of brake -B2-(code letters=>from Page 37-157
•     B -    Gearboxes with a shim and a retaining ring fitted on brake -B2- (code letters=>from Page 37-165

Special tools and workshop equipment required

• ◆ Adjustment appliance 3459

Adjusting 2nd and 4th gear brake -B2-

This adjustment instruction is only valid for gearboxes where a corrugated spring washer in brake -B2- on the last outer plate is installed (=> Items 10 and 11).

Gearbox code letters

=> from Page 00-3.

On these gearboxes the play of brake -B2- is determined by the thickness of the last outer plate(s) -Item 10-.

Note:

Adjusting gearboxes without corrugated spring washer.

• ‒ To adjust, install components without corrugated washer (item 11), without last outer plate (item 10) and without spring caps (item 6).

• Gearbox housing
• Circlip
• ◆ For supporting tube
• ◆ Installation position: Open ends face toward retaining wedge of free wheel
• Supporting tube -B2-
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Insert so that notch locates on freewheel wedge

• Outer plate -B2-
• ◆ 3 mm thick
• Spring cap
• ◆ Install after installing first outer plate (item 4)
• Spring cap
• ◆ Do not install when adjusting -B2-
• ◆ Install before installing last outer plate
• Spring
• Inner plate -B2-
• ◆ Quantity => from Page 00-3
• ◆ Spare part is allocated according to gearbox code letters

• Outer plate -B2-
• ◆ Always install 2 mm thick outer plates
• ◆ Quantity => from Page 00-3
• Outer plate -B2-
• ◆ Do not install when adjusting -B2-
• ◆ To adjust, 2 outer plates can be installed.
• Corrugated washer
• ◆ Do not install when adjusting -B2-

Calculating thickness of last outer plate -D-

→ The thickness of the outer plate(s) is determined by gap "x". Gap "x" is calculated using the following formula:

x = a - b - 3.6 mm

The illustration shows a cross-section of the brake -B2- in assembled form. Special tool 3459, which exerts a force onto the set of plates, is not illustrated.

3.6 mm is the allowance for settling resulting from the force exerted by special tool 3459.

Note:

The first outer plate -arrow- is 3 mm thick.

Calculating measurement "a"

Assemble planetary gearbox up to the last -B2- inner plate,
=> Page 37-113. The last outer plate, the last 3 spring caps and the corrugated washer are not installed.

• ‒ Place special tool 3459 onto the last inner plate and turn so that the 3 clips align with the holes for the ATF pump.
• ‒ Bolt special tool to flange for ATF pump: tightening torque 5 Nm.

Note:

The plate set for -B2- is now pressed together for measurements.

• ‒ → Measure from pump flange/gearbox housing -arrow- to 3459 with depth gauge.

Dimension a = Height of 3459 in mm - measured value

Example:

• ‒ Remove special tool 3459.

Calculating measurement "b"

• ‒ Push piston into ATF pump onto stop.
• ‒ Place paper gasket onto ATF Pump.
• ‒ → Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.

Example:

x = a - b - 3.6 mm

= 30.2 mm - 20.6 mm - 3.6 mm = 6.0 mm

• ‒ Determine thickness of outer plate(s) according to table. Part numbers

=> Parts catalogue

Table of outer plates -D-

• ‒ Fit three spring caps onto the compression springs.
• ‒ Install last outer plate(s) as selected from table.
• ‒ Install corrugated washer
• ‒ Further installation instructions => Page 37-127.

Adjusting 2nd and 4th gear brake -B2-

These adjustment procedures are only valid for gearboxes with a shim and retaining ring installed in brake -B2-
(=> Items 11 and 12).

Gearbox code letters

=> from Page 00-3.

In these gearboxes the play in brake -B2- is determined by the thickness of the shim -Item 11-.

Note:

Adjusting gearboxes with corrugated spring washer=> Page 37-157.

• ‒ To adjust, install components without shim (Item 11), without last outer plate (Item 10) and without spring caps (Item 6).

• Gearbox housing
• Circlip
• ◆ For supporting tube
• ◆ Installation position: Open ends face toward retaining wedge of free wheel
• Supporting tube -B2-
• ◆ Spare part is assigned according to gearbox code letters
• ◆ Insert so that notch locates on freewheel wedge

• Outer plate -B2-
• ◆ 3 mm thick
• Spring cap
• ◆ Install after installing first outer plate (Item 4)
• Spring cap
• ◆ Do not install when adjusting -B2-
• ◆ Install before installing last outer plate
• Spring
• ◆ Spare part is allocated according to gearbox code letters
• Inner plate -B2-
• ◆ Quantity => from Page 00-3
• ◆ Spare part is allocated according to gearbox code letters

• Outer plate -B2-
• ◆ Always install 2 mm thick outer plates
• ◆ Quantity => from Page 00-3
• Outer plate -B2-
• ◆ 3 mm thick
• ◆ Do not install when adjusting -B2-
• Shim
• ◆ Do not install when adjusting -B2-
• Retaining ring
• ◆ Inserted with smooth side facing last inner plate (Item 8) when adjusting -B2-

→ Determining thickness of shim(s)

The thickness of the shim depends on the size of gap "x". Gap "x" is calculated using the following formula:

Gap x = a - b - 2.65 mm

The illustration shows a cross-section of the brake -B2- in assembled form. Special tool 3459, which exerts a force -F- onto the set of plates, is not illustrated.

2.65 mm - The amount for settling is taken into account by force F.

•     1 -    ATF pump
•     2 -    Retaining ring
•     3 -    -B2- plates without last outer plate
•     4 -    Supporting tube

Notes:

• ◆ The first outer plate -arrow- is 3 mm thick.
• ◆ For measuring purposes do not insert last outer plate.

Calculating "a":

Assemble planetary gearbox up to the last -B2- inner plate, => Page 37-113. The last outer plate and shim are not installed.

• ‒ → Place retaining ring with smooth side onto last inner plate.
• ‒ Place 3459 onto retaining ring and turn so that the 3 clips align with the 3 holes for the ATF pump.
• ‒ Bolt special tool to flange for ATF pump: tightening torque 5 Nm.

Note:

The plate set for -B2- is now pressed together for measurements.

• ‒ → Measure from pump flange/gearbox housing -arrow- to 3459 with depth gauge.

Dimension a = Height of 3459 in mm - measured value

Example:

• ‒ Remove special tool 3459.
• ‒ Remove retaining ring.

Calculating "b":

• ‒ Push piston into ATF pump onto stop.
• ‒ Place paper gasket onto ATF Pump.
• ‒ → Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.

Example:

→ Gap x = a - b - 2.65 mm

Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm

• ‒ Determine size of shim(s) according to table. Part numbers

=> Parts catalogue

Table of shims:

• ‒ Fit three spring caps onto the compression springs.
• ‒ Insert last outer plate -3 mm thick-.

• ‒ → Install shim(s) -a- as selected from table.
• ‒ Place retaining ring -b- onto shim(s). Smooth side facing shim.
• ‒ Further installation instructions => Page 37-127.