Audi Workshop Service and Repair Manuals

Components Gearbox t  Allocate bolts and other components according to gearbox code letters, refer to → Electronic parts catalogue. t  Thoroughly clean all joints and connections and the surrounding areas before dismantling. t  When exchanging or repairing the manual gearbox, check the oil level and fill up with oil if necessary → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.34. t  Verify capacities and specifications according to the corresponding code letters → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.00. Sealants t  Thoroughly clean housing contact surfaces before applying sealing paste. t  Apply sealing paste -AMV 188 001 02- evenly and not too thickly. t  Breather holes must remain free of sealing paste. O-rings, oil seals and gaskets t  Always renew O-rings, oil seals and gaskets after removal. 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  Thoroughly clean housing joint surfaces before assembling.

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 before installation to prevent them from being trapped and damaged during assembly. t  After renewing oil seals and gaskets, check and, if necessary, top up oil level in gearbox → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.34.

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-.

Bolts and nuts 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  The tightening torques stated apply to non-oiled nuts and bolts. t  Always renew self-locking bolts and nuts. 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.

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  Do not install shims which are damaged or not in perfect condition. Bearings t  Install needle bearings, ball sleeves and roller bearings so the lettering (side with thicker metal) faces towards the installing tool. t  Lubricate all bearings in gearbox with gear oil when 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  Heat inner races of needle bearings and roller bearings to max. 130 °C. 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. Gear wheels, synchro-hubs, inner races for selector gears t  Before installing, heat inner races for selector gears to approx. 100° C using inductive heater -VAS 6414-. t  Use inductive heater -VAS 6414- to heat gear wheels and synchro-hubs 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 t  After installing, check that 1st to 6th speed selector gears have an axial clearance of 0.15 ... 0.50 mm and check that they rotate freely.

Input shaft t  If there is visible damage on the surface of the input shaft in the vicinity of the needle bearing for the dual-mass flywheel -arrow-, both the input shaft and the needle bearing in the dual-mass flywheel must be renewed. l  Renewing input shaft → Chapter „Dismantling and assembling gearbox - assembly sequence“ l  Renewing needle bearing in dual-mass flywheel → Chapter „Renewing needle bearing for dual-mass flywheel (Sachs and LuK versions)“

t  Check the input shaft for scoring around the bearing in the drive plate -arrow-. Renew the needle bearing in the drive plate if necessary → Rep. gr.13. Synchro-rings t  Do not interchange. When reusing synchro-rings, always fit to the same selector gear. t  Check for wear; renew if necessary. t  Lubricate with gear oil before installing.

Checking molybdenum-coated synchro-rings -I- and carbon-coated synchro-rings -II- → Chapter

Checking synchro-rings for 1st and 2nd gear t  Check the coated contact surfaces -arrows 2- on intermediate ring -B- for damage (flattened sections or particles of carbon coating broken away). t  Check inner contact surface -arrow 1- on synchro-ring -A- and outer contact surface -arrow 4- on inner ring -C- for grooves or scoring. t  Check for damage to coating on inner rings -C- with coated contact surface -arrow 3- (particles of carbon coating broken away).

Abnormal wear on selector gears and locking collars 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 -  Undamaged 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 t  Always renew synchro-rings with carbon coating together with locking collar. Renew selector gears also if there are traces of wear.