Audi Workshop Service and Repair Manuals

Assembling planetary gearbox Special tools and workshop equipment required

t  Assembly ring -3267- Procedure   Note t  When installing an exchange component, use all new parts supplied with the exchange component; do not reuse old parts. t  The planet carrier must be adjusted after renewing planet carrier, large sun gear, large input shaft or small input shaft → Chapter.

–  Insert O-ring -arrow- in planet carrier.

–  Fit axial needle bearing with washers and planet carrier in input gear in the sequence stated. 1 -  Input gear (is installed in gearbox housing) → Item 2 -  Washer for axial needle bearing; insert smooth side into input gear 3 -  Axial needle bearing 4 -  Washer for axial needle bearing 5 -  Planetary carrier with O-ring fitted

–  Place washer and axial needle bearing on small sun gear in planet carrier. –  Centralize washer and axial needle bearing in small sun gear.   Note t  Reverse gear brake “B1” must be adjusted when renewing the following components → Chapter: t  Freewheel t  Piston for reverse gear brake “B1” t  Plates t  Gearbox housing –  Insert shim(s). –  Insert inner and outer plates “B1”. –  Insert pressure plate with flat side facing plates.   Note The thickness of the pressure plate varies depending on the number of plates → Item and the replacement part is assigned to the gearbox code.

–  Insert dished spring with convex side facing towards freewheel.

–  Preload freewheel rollers with assembly ring -3267- and insert freewheel.

–  Install circlip -b- for freewheel and circlip -a- for supporting tube. –  Fit gaps of circlips over retaining wedge -arrow- of freewheel. –  Install gearbox speed sender -G38- → Chapter. –  Measure “B1” to check adjustment → .

–  Fit components into gearbox housing in the sequence stated: 1 -  Large sun gear 2 -  Washer for axial needle bearing (shoulder must face large sun gear) 3 -  Axial needle bearing 4 -  Large input shaft 5 -  Axial needle bearing 6 -  Needle bearing 7 -  Small input shaft

–  Engage parking lock. –  To tighten the bolt for the small input shaft, insert a screwdriver through one of the holes in the large sun gear.

–  Insert shim -3- onto shoulder of small input shaft -arrow-.   Note Determine thickness of shim → Chapter. –  Fit bolt -1- for small input shaft with washer -2- and tighten. l  Tightening torque: 30 Nm –  Carry out check measurement of planet carrier → Anchor.

–  Lubricate new O-ring with ATF. –  Insert O-ring in groove of turbine shaft -arrow-.   Note Depending on version, clutches “K1” and “K3” must be pressed together before installing. –  Check whether clutch “K1” can be fully fitted onto splines of turbine shaft of “K3”. –  Fit clutch “K1” onto “K3” by hand.

l  If splines -arrow 1- in hub of “K1” are visible, the two clutches must be pressed together → Chapter.

l  If the resistance of the O-ring is overcome when the two clutches are fitted together (by hand!), the splines -arrow 1- of “K1” are no longer visible. The clutches then no longer need to be pressed together. –  Continue to assemble gearbox.

–  Clip axial needle bearing with washer -1- onto 3rd and 4th gear clutch “K3”-item 2-. l  Installation position: washer of bearing faces “K3”.   Note Moisten washer of axial needle bearing with ATF so that it sticks to “K3”.

–  Ensure piston rings seat correctly on “K3”. –  Ensure that the ends of the piston rings are hooked together.

–  Insert 3rd and 4th gear clutch “K3” with axial needle bearing and washer.   Note t  If “K1” and “K3” are pressed together, the two clutches can only be installed together as one unit. t  If “K1” and “K3” are not pressed together, it is easier to fit the two clutches individually. t  When installing, rotate clutch until all the plates have meshed.

–  Insert shim(s) -arrow- in “K1”.   Note t  When renewing “K1”, “K2”, the small input shaft or the ATF pump the shim must be measured again → Chapter. t  Up to 3 shims can be installed.

–  Insert reverse gear clutch “K2”.   Note When installing, rotate reverse gear clutch “K2” until all the plates have meshed. –  Insert supporting tube for clutch pack of 2nd and 4th gear brake “B2” in such a way that recess on lower part of supporting tube engages in retaining wedge of freewheel.

–  Install plates of 2nd and 4th gear brake “B2” in the sequence stated: 1.  First insert a 3 mm thick outer plate. 2.  Insert three spring caps in outer plate. 3.  Insert compression springs -arrows-. 4.  Insert all plates with the exception of the last outer plate. 5.  Fit three spring caps on compression springs.   Note t  Adjust 2nd and 4th gear brake “B2” when renewing the following components: t  Gearbox housing t  Supporting tube t  ATF pump t  Corrugated washer t  Retaining ring t  Plates t  These replacement parts must be allocated according to the gearbox code.

There are two versions of brake “B2”: A -  Brake with corrugated washer B -  Brake with retaining ring Gearboxes in which a corrugated washer is fitted on the last outer plate in brake “B2” (code letters → Chapter):   Note On these gearboxes, the thickness of the last outer plate determines the clearance of brake “B2”. Determining required thickness of last outer plate → Chapter. –  Fit last outer plate after determining required thickness.   Note If the measurement requires two outer plates to be installed, they must be fitted onto the spring caps together. –  Install corrugated washer. Gearboxes in which a shim and a retaining ring are fitted in brake “B2” (code letters → Chapter):   Note

On these gearboxes, the last outer plate is always 3 mm thick. The clearance of brake “B2” is determined by the shim -a- on which the retaining ring -b- is fitted. –  Fit last outer plate with a thickness of “3 mm”. –  Determine thickness of required shim → Chapter and install shim. –  Fit retaining ring onto shim. l  Installation position: smooth side faces shim

Continued for all gearboxes: –  If fitted, clean strainer and install.   Note The strainer is installed in the return pipe of the ATF cooler. It cannot be retrofitted in older gearboxes. –  Insert gasket for ATF pump, paying attention to position of holes. –  Lightly lubricate new O-ring with ATF and fit O-ring on ATF pump.   Note Ensure the piston rings are properly seated.

Caution Do not damage O-ring when inserting ATF pump. –  Insert ATF pump and push onto stop by hand. –  Tighten bolts evenly in diagonal sequence. Tightening torque: l  8 Nm and then turn 90° further. –  Carry out check measurement of clutch play → Anchor.

–  Fit sealing plug with O-rings. l  Installation position: lug -arrow- engages in oil passage. –  Install valve body with conductor strip → Chapter. –  Install ATF oil pan → Chapter. –  Install torque converter → Chapter, note assignment → Chapter. –  Install gearbox → Anchor. –  Fill up with ATF after repairs → Chapter.