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A4 Mk2

Components
Components
Gearbox
t  When installing the gearbox, ensure that the dowel sleeves between the engine and the gearbox are correctly located.
t  When installing mounting brackets as well as other waxed components, the contact surfaces must be cleaned. The contact surfaces must be free of wax and grease.
t  Allocate bolts and other components according to gearbox code letters, refer to → Electronic parts catalogue.
t  When installing a new gearbox, check the oil level and fill up with oil if necessary → Chapter.
t  Capacities and specifications → Chapter
t  Thoroughly clean all joints and connections and the surrounding areas before dismantling.
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 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.
  N32-0001
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.
  N30-10172
t  Renew spring pins. Position: the slit -A- should be in line with the line of force -arrow-.
  A34-0149
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.
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  On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is renewed → Chapter.
t  Note assembly instructions for SAC pressure plate → 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.
  N00-0383

Special tools > < General repair instructions