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. t  When installing a new gearbox, check the oil level and fill up with oil if necessary → Chapter. t  Capacities and specifications → Chapter t  When installing a new rear final drive unit, check the oil level in the final drive and top up if necessary. Allocation → Chapter „Identification of rear final drive units 01R, 0AR and 08V“. 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 housing contact surfaces 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 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  Always renew self-locking bolts and nuts. 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.

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. Bearings t  Install needle bearings, ball sleeves and roller bearings so the lettering (side with thicker metal) faces towards the installing tool. t  Lubricate all bearings in gearbox with gear oil when 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  Grease needle bearing for gearbox input shaft in rear side of flywheel. 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). Gear wheels, synchro-hubs, inner races for selector gears t  Before installing, heat inner races of needle bearings for selector gears to approx. 100° C using inductive heater -VAS 6414-. t  Use inductive heater -VAS 6414- to heat gear wheels and synchro-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.

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. Clutch actuation t  When removing gearbox, remove clutch slave cylinder without disconnecting pipes. t  Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic pipe is still connected. Otherwise the piston will be pressed out of the clutch slave cylinder. As a result the clutch 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 „Notes on removing and installing clutch master cylinder and slave cylinder“). 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.