Audi Workshop Service and Repair Manuals

Components Gearbox t  Allocate bolts and other components according to gearbox code letters; refer to → Electronic parts catalogue → Chapter „Code letters, allocation, transmission ratios, capacities“. t  After installing a replacement gearbox, check oil level and fill up with gear oil as required → Chapter. t  Capacities and specifications → Chapter „Code letters, allocation, transmission ratios, capacities“ t  Thoroughly clean all joints and connections and the surrounding areas before dismantling. t  When installing gearbox ensure dowel sleeves are correctly seated. Sealants t  Thoroughly clean joint surfaces on gearbox housing etc. 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. 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 gaskets and oil seals, check and, if necessary, top up oil level in gearbox → Chapter. 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-.

Nuts, bolts 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  Renew self-locking nuts and bolts. 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. Bearings t  Lubricate all bearings in gearbox housing with gear oil before 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  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. t  Install needle bearings, ball sleeves and roller bearings so the lettering (side with thicker metal) faces towards the installing tool. t  Mark the needle bearings of the selector gears when removing. This ensures the same installation position when re-installing. t  Grease needle bearing for gearbox input shaft in rear of flywheel.

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. Gears, synchronising hubs, inner rings for selector gears t  Before installing, heat inner rings for selector gears to approx. 100° C using inductive heater -VAS 6414-. t  Use inductive heater -VAS 6414- to heat gear wheels and synchronising 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 1st to 6th speed selector gears for minimal axial play and freedom of movement.

Input shaft t  Check the input shaft for scoring around the bearing in the crankshaft/flywheel -arrow-. Renew the needle bearing in the crankshaft 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 when installing.

Checking synchro-rings with molybdenum coating t  Clean synchro-ring; the friction surface must be free of oil. t  The friction surface of an intact molybdenum coated synchro-ring has a graphite-grey, slightly porous appearance. t  The synchro-ring must be renewed if very shiny areas -A- have formed on the friction surface or if the brass-coloured metal underneath is already visible.

Checking synchro-rings for 1st and 2nd gear Check the coated contact surfaces -arrows 2- on intermediate ring -B- for damage (flattened sections or particles of carbon coating broken away). Check inner contact surface -arrow 1- on synchro-ring -A- and outer contact surface -arrow 4- on inner ring -C- for grooves or scoring. 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 -  Intact 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. Clutch actuation, clutch t  When removing gearbox, remove clutch slave cylinder without disconnecting pipes. t  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. As a result the slave cylinder will be destroyed. t  If the clutch pedal does not return to its initial position after releasing it (clutch pedal in rest position), you must bleed the clutch system (further measures → Chapter). t  The clutch system should be bled at the same intervals as the brake system → Booklet45. t  Note assembly instructions for SAC pressure plate → Chapter. t  On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is renewed → Chapter. t  If the clutch has burnt out, thoroughly clean the gearbox housing in area of clutch and parts of the engine facing the gearbox in order to prevent odours. t  Only blow out dual-mass flywheel with compressed air.