audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

ABOUT US
Rules for cleanliness when working on 5-speed manual gearbox > < Notes on tow-starting and towing

A2

Repair instructions
Repair instructions
Proper tools and the maximum possible care and cleanliness are essential for satisfactory repairs. The usual basic safety precautions also naturally apply when carrying out repair work.
To avoid repetition, a number of generally applicable instructions for the various repair procedures are summarised here. They apply to the work described in this Manual.
Fault-finding, vehicle self-diagnosis and measurement
t  Before performing gearbox repairs the cause of the trouble should be identified as accurately as possible → Rep. gr.01.
  Note
Before performing servicing work on the selector mechanism and hydraulic system of the 5-speed manual gearbox 085 DS, the electrical components can be checked using the self-diagnosis routine → Rep. gr.01.
Environmental and waste disposal regulations for oil
t  ATF, gear oil and any other type of oil must be handled with care.
t  Dispose of drained oil properly.
t  Always adhere to statutory environmental and waste disposal regulations.
t  Observe the information shown on the packaging of the oil.
Special tools
For a complete list of special tools used in this Workshop Manual → "Special tools, Workshop equipment"
Gearbox
t  Rules for cleanliness when working on manual gearboxes → Chapter.
t  Do not run the engine and do not tow the vehicle with the gearbox housing cover detached or without gear oil.
t  For gearbox replacement, refer to → Chapter „Checking gear oil level and topping up“. Capacities → Chapter, specifications → Electronic parts catalogue.
t  When installing gearbox, ensure that dowel sleeves are fitted correctly.
O-rings, seals, gaskets and oil seals
t  Always renew O-rings, seals and gaskets.
t  After removing gaskets and 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 seals faces toward the side with fluid filling.
t  When installing a new oil seal, position the seal in the housing so 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  Check oil level in manual gearbox after installing new seals and gaskets → Chapter.
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.
  N32-0001
Locking elements
t  Do not over-stretch circlips.
t  Renew circlips which have been damaged or over-tensioned.
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  The bolts and nuts securing covers and housings should be loosened and tightened diagonally.
t  Take care to keep sensitive components - e.g. clutch pressure plates - straight. They should only be unfastened and tightened diagonally and in stages.
t  The tightening torques stated apply to non-oiled nuts and bolts.
t  Always renew self-locking bolts and nuts.
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  Install needle bearings so the lettering (side with thicker metal) faces towards the installing tool.
t  Lubricate all bearings in gearbox housing with gear oil before installing.
t  Heat inner races of taper roller bearings to approx. 100 °C before installing. On assembly press home with no axial clearance.
t  Do not interchange inner or outer races of bearings of the same size.
t  Always renew the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.
Shims
t  Measure shims at several points with a micrometer. 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. When re-using synchro-rings, always fit to the same gear.
t  Check for wear and renew if necessary.
t  Lubricate with gear oil before installing.
Gear wheels
t  Before pressing on, clean and heat to approx. 100 °C on a hot plate.
t  The temperature can be checked with temperature tester -V.A.G 1558-.
Selector gears
After installing, check that the 1st to 5th speed selector gears have a slight amount of axial clearance and move freely.
Clutch
t  When removing gearbox, remove clutch slave cylinder without disconnecting pipes.
t  Make sure the clutch pressure plate is kept straight; slacken off and tighten in small stages.
t  If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the gearbox in order to prevent odours.
  A34-0149

Rules for cleanliness when working on 5-speed manual gearbox > < Notes on tow-starting and towing