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 naturally also apply when carrying out vehicle repairs.

A number of generally valid instructions governing the various repair procedures - which used to be repeated several times throughout the Workshop Manual - are summarised here and apply to this Workshop Manual.

Special tools

For a list of special tools used in this Workshop Manual, refer to

=> "Special Tools, Workshop Equipment" binder

Gearbox

• ◆ On replacing manual gearbox or rear final drive, check oil level and top up if necessary .
• ◆ Reconditioned gearboxes for S4 and RS4 (with gear oil cooling) contain an additional 0.3 litres of gear oil for gear oil cooling pipes. On gearbox replacement, gear oil pipes/gear oil cooler must therefore be completely drained.

• ◆ Capacities and specifications => Page 00-14 onwards.
• ◆ Carefully clean all joints and adjacent areas before disconnecting.
• ◆ Ensure correct fit of dowel sleeves when installing gearbox.

Locking elements

• ◆ Take care not to strain circlips.
• ◆ Always replace damaged or strained circlips.
• ◆ Circlips must be properly positioned in groove.
• ◆ → Replace spring pins. Installation position: Slot -A- in line with direction of force -arrow-.

Sealant

• ◆ Thoroughly clean housing joint surfaces before applying sealing paste.
• ◆ Apply sealing paste AMV 188 000 02 or AMV 188 001 02 evenly and not too thickly.
• ◆ No sealing paste should be allowed to enter vent holes.

O-rings, oil seals, gaskets

• ◆ Always replace O-rings, oil seals and gaskets.

• ◆ After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• ◆ Thoroughly clean housing joint surfaces prior to assembly.
• ◆ → Before installing radial shaft oil seals, lubricate outer diameter slightly and half fill space between sealing lips -arrow- with sealing grease G 052 128 A1.
• ◆ Open sides of oil seals face fluid side.
• ◆ Press in new oil seal such that sealing lip is not at same location as sealing lip of old oil seal (make use of insertion depth tolerance).
• ◆ On insertion, lubricate O-rings slightly to stop them being crushed on assembly.
• ◆ After replacing gaskets and oil seals, check oil level .

Bolts and nuts

• ◆ Slacken off bolts/nuts in reverse tightening sequence.
• ◆ Slacken off and tighten bolts and nuts for securing covers and housings in diagonal sequence.
• ◆ Take care not to tilt particularly sensitive components such as clutch pressure plates and slacken off/tighten gradually in diagonal sequence.
• ◆ Tightening torques specified apply to non-lubricated bolts and nuts.
• ◆ Always replace self-locking bolts and nuts.
• ◆ Clean threads of bolts fitted using locking fluid with a wire brush. Then insert bolts and apply AMV 185 101 A1.
• ◆ Tapped holes into which self-locking bolts or bolts fitted using locking fluid have been inserted must be cleaned (e.g. using a thread cutter). Otherwise there would be a danger of the bolts shearing off on renewed disassembly.

Bearings

• ◆ Install needle bearings with labelled side (thicker metal) facing fitting tool.
• ◆ Mark needle bearings of 1st to 6th speed sliding gears on removal to ensure the same installation position on fitting.
• ◆ Grease needle bearing for rear gearbox input shaft in flywheel.
• ◆ Apply gear oil to all bearings on installation in gearbox housing.
• ◆ Heat inner races of taper roller bearings to approx. 100 °C before installing. Press home as far as stop on assembly so that there is no axial clearance.
• ◆ Take care not to interchange outer and inner races of bearings of the same size.
• ◆ Taper roller bearings fitted on one shaft are to be replaced as a set using the same make of bearings.
• ◆ Taper roller bearings for output shaft and differential in manual gearbox are of low-friction design. Do not apply any extra oil to new taper roller bearings for friction torque measurement. The bearings are treated with a special oil at the factory for this purpose.

Shims

• ◆ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
• ◆ Check for burrs and damage.
• ◆ Only install shims which are in perfect condition.

Gear wheels, synchro-hubs, inner races for sliding gears

• ◆ Heat gear wheels and synchro-hubs to approx. 100°C before installing. Press home as far as stop on assembly so that there is no axial clearance.
• ◆ Heat inner races for sliding gears to approx. 100 °C before installing.
• ◆ Temperature can be checked using temperature tester V.A.G 1558.
• ◆ Pay attention to installation position.

Sliding gears

• ◆ After installing, check that 1st to 6th speed sliding gears have an axial clearance of 0.15 ... 0.35 mm and move freely.

Synchro-rings

• ◆ Do not interchange synchro-rings; always fit to same gear if rings are re-used.
• ◆ Check for wear and replace if necessary.
• ◆ Apply gear oil on insertion.
• ◆ Gearboxes with code letters FZV, FZW and FZY are fitted with optimised synchro-rings in conjunction with a modified locking collar for 1st and 2nd gear. These optimised synchro components are available for service work on all 01E gearboxes => Page 35-35.

Clutch mechanism

• ◆ On removing gearbox, take out clutch slave cylinder without opening piping system.
• ◆ Do not press clutch pedal after removing slave cylinder as otherwise piston would be forced out of slave cylinder.
• ◆ Make sure clutch pressure plate is kept straight; slacken off and tighten bolts gradually in diagonal sequence.

• ◆ To reduce the odour nuisance of a scorched clutch, thoroughly clean bell housing, flywheel and parts of engine facing gearbox.
• ◆ Vehicles with 2.7l - 184 kW and 195 kW engine are fitted with an SAC pressure plate on which an adjuster ring has to be reset if only the clutch plate is replaced => Page 30-58.
• ◆ Heed fitting instructions for SAC pressure plate => Page 30-56.