Audi Workshop Service and Repair Manuals

Removing and installing chain and pulley set “I” Special tools and workshop equipment required

t  Fitting sleeves -3241-

t  Puller -T10055- t  Compressor tool -T40130- t  Press tool -T40131- t  Puller -T40132- t  Compressed air hose for tyre valves Removing Proceed as follows: –  Remove gearbox → multitronic 01J, front-wheel drive; Rep. Gr.37, → multitronic 0AN, front-wheel drive; Rep. Gr.37. –  Mount gearbox on assembly stand → Chapter. –  Remove end cover → multitronic 01J, front-wheel drive; Rep. Gr.38, → multitronic 0AN, front-wheel drive; Rep. Gr.38. –  Remove automatic gearbox control unit -J217- → Chapter. –  Remove hydraulic control unit → Chapter.

–  Remove axial sealing elements -A- (4x) and -B-.   Note The axial sealing elements must be renewed.

–  Remove cover -arrow- from sender wheel “II”.

–  Use 2 screwdrivers to lever off sender wheel “II”-arrows-.   Note The sender wheel must be renewed.

–  Use puller -T40132- and puller -T10055- to remove sender wheel “I”.   Note The sender wheel must be renewed.

–  Lift out oil pipe -arrow- by hand.   Note Do not use a tool to avoid damaging the sealing surfaces.

–  Remove circlip -3- from shaft -item 1- for pulley set “I”. –  Mark and remove shim -2-.   Caution There is a risk that parts may be interchanged. t  Make sure not to interchange thrust washer → Item and shim -2- underneath circlip -3-. t  Attach shim -2- to circlip -3- by means of a cable tie to prevent the parts from being interchanged.

–  Remove bolts for intermediate housing -arrow-; note different lengths and mark installation position of bolts if necessary. –  Detach intermediate housing.

–  Mark thrust washer -1- and remove from pulley set “I”-item 3-. –  Remove spacer -2- (only fitted on certain versions!) from pulley set “I”.   Caution There is a risk that parts may be interchanged. t  Make sure not to interchange thrust washer -1- and shim → Item underneath circlip. t  Mark thrust washer -1- with paint.

–  Remove gasket -1- for intermediate housing. –  Remove dowel sleeve -3-.   Note t  Dowel sleeve -3- must be removed so that support bracket -T40130/1- can be attached to gearbox. t  Dowel sleeve -2- can remain inserted in gearbox.

–  Carefully disengage retaining pins -arrows- and detach oil guide “I”-item 1-.

–  Lift out oil guide “II”-arrow-.

Measure height of chain:   Note The height of the chain pins is used as a measure of chain height. –  Measure height -a- of chain pin -1-.   Note t  Illustration shows sectional view of chain and chain pin -1-. t  The following two procedures differ according to the chain height. Gearboxes with chain height -a- = 34 mm:

–  Place adapter -T40130/2- on pulley set “II”. l  Check for correct positioning of the O-rings in the adapter -T40130/2-. Both O-rings must be fitted. l  O-rings in adapter -T40130/2- and sealing surfaces on pulley set must be clean and coated with ATF. –  Align support bracket -T40130/1- centrally on adapter -T40130/2- and bolt support bracket onto gearbox housing -bottom arrows-, as shown in illustration. –  Screw in bolt -1- until adapter -T40130/2- is pressed against pulley set “II”. –  Connect compressed air hose -2- for tyre valves to adapter -T40130/2- and apply approx. 3 bar. l  The pulley set should open and the chain should relax. –  Slide in the two arresters in the direction of the -arrows- to secure the top side of the pulley. –  Lock the arresters in this position using the knurled screws, taking care not to trap the chain.

Gearboxes with chain height -a- = 38 mm:

–  Place adapter -T40130/2- on pulley set “II”. l  Check for correct positioning of the O-rings in the adapter -T40130/2-. Both O-rings must be fitted. l  O-rings in adapter -T40130/2- and sealing surfaces on pulley set must be clean and coated with ATF. –  Align support bracket -T40130/1- centrally on adapter -T40130/2- with spacers -T40130/5- and -T40130/6-, and bolt support bracket onto gearbox housing -bottom arrows-, as shown in illustration. –  Screw in bolt -1- until adapter -T40130/2- is pressed against pulley set “II”. –  Connect compressed air hose -2- for tyre valves to adapter -T40130/2- and apply approx. 3 bar. l  The pulley set should open and the chain should relax. –  Slide in the two arresters in the direction of the -arrows- to secure the top side of the pulley. –  Lock the arresters in this position using the knurled screws, taking care not to trap the chain. Continued for gearboxes with any chain height:

–  Turn chain until link with production date stamp -A- is visible. –  Open chain at fourth chain pin away from link with date stamp. –  Place cloth under chain to prevent welding spots from falling into gearbox. –  Break off welding spots on both halves of the fourth chain pin -arrow- on bottom of chain. –  Lift out the two-piece chain pin.   Caution Do not kink the chain (risk of damage).

–  Mark installation position of guide rail -2- for refitting. –  Unclip guide rail at oil pipe -1- and detach chain and guide rail.

–  Lift out pulley set “I”-arrow-. Installing l  Tightening torques → Chapter   Caution t  Assess wear on bearing “D” and bearing “E” → Chapter. t  Assess wear on chain, pulley sets “I” and “II”, bearing “C” and suction-jet pump → Chapter.   Note If the pulley set “I” is replaced, the shim and circlip must be re-determined → Anchor. –  Carefully insert pulley set “I”-arrow- into roller bearing. l  Splines must engage in splines on input shaft. –  Clean the chain. Remove any swarf between the links.

–  Clip guide rail -2- onto oil pipe -1- with chain inserted (refer to marking made upon removal to facilitate installation).

–  Feed chain through until the two open ends meet. –  Tension the open ends of the chain with one cable tie -1- each as shown.   Note Tensioning with the cable ties keeps the links in parallel and firmly in position and makes sure they are straight on assembly. –  Join chain -arrows- so that all of the links are sitting straight and parallel to each other.

l  The distance between the links -arrow- varies for design reasons.

–  Insert the two halves of the chain pin -1- and -2- from above, as shown in illustration. l  The welding spots which are still intact -arrows- should be nearest the top. l  The welding spots which were broken off the chain pin should be nearest the bottom. l  The two halves of the chain pin are asymmetrical in shape. –  Remove the cable ties attached from the chain.

–  Release knurled screws and slide arresters outwards in opposite direction of -arrows-. –  Disconnect compressed air hose -2- for tyre valves from adapter -T40130/2-. –  Release air from adapter -T40130/2- via compressed air valve. l  This is done by pressing down the valve needle with a small screwdriver. l  The pulley set should close and the chain should tighten.

–  Insert oil guide “II”-arrow-.

–  Insert oil guide “I”-item 1-. l  Retaining pins -arrows- must fit into holes on gearbox housing.

–  If applicable, fit the spacer -2-. Heed the installation position as shown in the sectional view. –  Fit spacer -2- (if one was installed). Note installation position, as illustrated in sectional view.   Note If a spacer -2- was fitted on pulley set “I”, it should only be installed again if the existing bearing “D” (with inner race) has not been renewed. A spacer must not be installed in conjunction with a bearing “D” which does not have an inner race.   Caution There is a risk that parts may be interchanged. Make sure not to interchange thrust washer -1- and shim → Item underneath circlip.

–  Fit gasket -1- for intermediate housing. –  Check that dowel sleeves -2 and 3- are fitted and insert if necessary.

–  Fit intermediate housing. –  Screw in bolts -arrow- for intermediate housing and tighten diagonally in stages. l  The bolts can have different lengths, depending on the version.   Note

If the same pulley set “I” has been re-installed, fit the old shim and a new circlip – with the same thickness as the old circlip. –  Turn gearbox housing on assembly stand so that pulley set “I” rests against intermediate housing under its own weight.   Note This allows the circlip -3- to be inserted in the groove on the shaft and ensures that the bearing is not damaged when the sender wheel “I” is subsequently fitted. –  Fit marked shim -2- onto shaft for pulley set “I”-item 1-. –  Insert new circlip -3- into groove on shaft for pulley set and press home. l  Note installation position: the drillings in the eyes of the circlip are tapered. The smaller side faces upwards. l  The circlip must be properly seated in the base of the groove.   Note

t  The following illustration is shown with the intermediate housing on top, contrary to the true gearbox position. t  Always renew sender wheels “I” and “II”. –  Using a rubber-headed hammer, carefully knock new sender wheel “I” with press tool -T40131--arrow- all the way onto shaft.

–  Pull the assembly aid -3241/2- out of the fitting sleeve -3241/1-. –  Using a rubber-headed hammer, carefully knock home the new sender wheel “II” with the fitting sleeve -3241/1-. –  Turn gearbox on assembly stand so that intermediate housing is facing upwards again.

–  Insert oil pipe -arrow- by hand.   Note Do not use a tool to avoid damaging the sealing surfaces.

–  Fit cover -arrow- on sender wheel “II”. l  The locking element on the back of the cover must be inserted in the small hole on the surface of the gearbox. –  Install hydraulic control unit → Chapter. –  Install automatic gearbox control unit -J217- → Chapter. –  Install end cover → multitronic 01J, front-wheel drive; Rep. Gr.38, → multitronic 0AN, front-wheel drive; Rep. Gr.38. –  Install gearbox → multitronic 01J, front-wheel drive; Rep. Gr.37, → multitronic 0AN, front-wheel drive; Rep. Gr.37.