Audi Workshop Service and Repair Manuals

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful gearbox repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Workshop Manual, are summarised here. They apply to this Workshop Manual.

Special tools

For a complete list of special tools used in this Workshop Manual

=> Booklet; Special tools, Workshop equipment

Gearbox

• ◆ Select the correct bolts and other components according to the gearbox code letters via the Parts Catalogue => from Page 00-3.
• ◆ When fitting a new gearbox, the oil level must be checked and oil added if necessary .
• ◆ Capacities and specifications => Page 00-3 onwards.
• ◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
• ◆ When installing gearbox, ensure that the dowel sleeves are fitted correctly.

Sealants

• ◆ Thoroughly clean housing joint surfaces before applying sealing paste.
• ◆ Apply sealing paste evenly, taking care to avoid excessively thick coating.
  - Sealing paste AMV 188 001 02 for gearboxes with aluminium or magnesium housing.
  - Sealing paste AMV 188 000 02 for gearboxes with aluminium housing only.
• ◆ Breather holes must remain free of sealing paste.

O-rings, seals, gaskets

• ◆ Always renew O-rings, seals and gaskets.
• ◆ 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.
• ◆ Thoroughly clean housing joint surfaces before assembling.

• ◆ → Before installing radial shaft oil seals, lightly oil outer circumference and fill space between sealing lips -arrow- with grease.
• ◆ The open side of the oil seals faces toward the side with fluid filling.
• ◆ When replacing oil seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
• ◆ Lightly oil O-rings before installing to prevent them being trapped and damaged when assembling.
• ◆ After renewing seals and gaskets check oil level in gearbox .

Locking elements

• ◆ Do not over-stretch circlips.
• ◆ Always renew circlips which have been damaged or over-tensioned.
• ◆ Circlips must be properly seated in the base of the groove.
• ◆ → Renew spring pins. Installation position: Slot -A- longitudinal to line of force -arrow-.

Nuts, bolts

• ◆ Slacken the nuts and bolts in reverse sequence to the specified tightening sequence.
• ◆ Nuts and bolts which secure covers and housings should be slackened and tightened crosswise in stages if no tightening sequence is specified.
• ◆ The tightening torques stated apply to non-oiled nuts and bolts.
• ◆ Always renew self-locking nuts and bolts.

• ◆ The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 A1 when inserting.
• ◆ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Mounting

• ◆ Attach the needle bearing with the written side (greater plate thickness) to the installing tool.
• ◆ Mark the needle roller bearings of 1st to 5th speed sliding gears when removing to ensure the same installation position when re-installing.
• ◆ Grease needle roller bearing for gearbox input shaft in flywheel.
• ◆ Lubricate all bearings in gearbox housing with gear oil before installing.
• ◆ Heat inner races of taper roller bearings to approx. 100 oC before installing. Press in onto stop when installing so there is no axial clearance.

• ◆ Do not interchange inner or outer races of bearings of the same size.
• ◆ Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
• ◆ The taper roller bearings for the output shaft and the differential in the gearbox are low-friction bearings. Do not additionally oil new taper roller bearings when measuring friction torque. The bearings are pre-treated at the factory with a special type of oil for this purpose.

Adjustment shims

• ◆ Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain exact shim thickness required.
• ◆ Check for burrs and damage. Install only adjustment shims which are in perfect condition.

Sliding gears

• ◆ After installing, check 1st to 5th speed sliding gears for axial clearance of 0.15 ... 0.35 mm and check that they rotate freely.

Synchroniser rings

• ◆ Do not interchange synchroniser rings. When reusing always fit to the same gear.
• ◆ Check for wear; replace if necessary.
• ◆ Coat with gearbox oil when installing

Gears, synchro-hubs, inner races for sliding gears

• ◆ Heat gears and synchro-hubs to approx. 100oC before installing. Press in onto stop when installing so there is no axial clearance.
• ◆ Heat inner races for sliding gears to approx. 100 oC when installing.
• ◆ Temperature can be checked with temperature tester V.A.G 1558.
• ◆ Note installation position.

Clutch mechanism

• ◆ When removing gearbox, remove clutch slave cylinder without disconnecting pipes.
• ◆ Do not depress the clutch pedal after removing the slave cylinder if the hydraulic pipe is still connected. Otherwise the piston will be pressed out of the slave cylinder.
• ◆ Do not tilt clutch pressure plate, loosen and tighten diagonally in small steps.
• ◆ If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the gearbox in order to reduce the smell.