lock AUDI A6 2000 C5 / 2.G 01E Transmission Bearing House And Torsen Differential Workshop Manual

34-59


- Remove locking bolts -A- for selector shaft from transmission housing.
- Mark installation positions of aluminium bolts and steel bolts; do not
interchange.
- Remove 3 bolts -B- for cover for selector shaft, take off cover.
- Pull out selector shaft.

- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do
this by moving 2 selector plates (arrows).
Pa
ge 7 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
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34-62


Note:
Use only hex bolt of tensioning sleeve 3116, length 50 mm. - Pull off 5th speed gear, to do this, block hollow shaft by engaging 2
gears Page 34
-59
.
C - Two arm puller, e.g. Kukko 20/10 with 200 mm long puller arms
- Remove shim -B- for 5th speed gear, note thickness and re-determine
if necessary Page 34
-78
.
- Take off spacer sleeve -A-.

Note:
Do not drive out roll pin, otherwise selector rod bearing will be damaged. - Press out roll pin -A- for selector fork for 5th and 6th gear.
- Pull selector rod on follower together with selector fork for 5th and 6th
gear and locking collar as far as possible away from bearing plate (until
stop is felt).
Pa
ge 10 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-63


- Mark installation position (arrow -3-) of locking collar for 5th and 6th
gear (arrow -1-) and synchro-hub -A- (paired).

- Pull follower together with selector fork and locking collar off selector
rod.
Pa
ge 11 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-64


- Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub
for 5th and 6th speed gears and inner race for 5th speed sliding gear.
A - Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks

- Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Mark fitting locations of aluminium and steel bolts. (Bolts must not be
interchanged when installing.)
- Drive out dowel sleeves on bearing plate and remove bearing plate
from transmission housing.
- Secure drive pinion relative to hollow shaft e.g. hose tie, to prevent it
falling out.
Pa
ge 12 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-70


- Fit relay lever -A- for reverse gear onto bolt for relay lever. Watch
position of pin when doing this (limits relay lever travel to synchro-ring).
- Insert sliding gear -B- and engage relay lever with groove on sliding
gear.
- Insert synchro-ring -C-.
Installation position: position flat on circumference of synchro-ring
towards input shaft (not as yet fitted) (arrow -1-)
- Insert spring.
Installation position: hook single angled end into recess on synchro-
ring (arrow -2-). Turn double angled end anti-clockwise and hook into
opening in bearing plate (arrow -3-)
Pa
ge 19 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-71


- Insert shaft -C-.
- Fit retaining plate -A-.

Installation position: chamfers of holes for locking pins of the
synchro-ring face bearing plate
- Insert spring clasp -B- into locking pins of the synchro-ring.
- Replace self-locking nut -D- and tighten to 25 Nm.

- Slide input shaft -A- with selector rod and selector fork for 3rd and 4th
gear at an angle into bearing plate.

Selector fork installation position: rib towards follower Page 34
-
52

Pa
ge 20 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-74

- Drive in 2 dowel sleeves for bearing
flange/transmission housing.

- Tighten 12 bolts using diagonal sequence to 25
Nm.

Note: - Screw in locking bolts for selector rods.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
Aluminium and steel bolts must not be interchanged when installing.Tightening torques: for aluminium locking bolts = 50 Nm, and for steel
locking bolts = 70 Nm
Pa
ge 23 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-77


Note: - Line up markings (arrow -3-) on paired synchro-hub -A- and locking
collar for 5th and 6th gear (arrow -1-).
- Fit locking collar (arrow -1-) with selector fork (arrow -2-) onto synchro-
hub -A- as well as follower for 5th and 6th gear -B- onto selector rod -
C- at the same time.
Selector fork rib (arrow -2-) must face towards shaft end. When sliding follower onto selector rod for 5th and 6th gear remember
holes for roll pin.

Note:
Do not drive in roll pin, otherwise selector rod mounting will be damaged. - Press in roll pin -A- flush.
Pa
ge 26 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-81


- Drive on inner race for 5th speed sliding gear free of axial play.
- Oil needle bearing with gear oil and fit.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th speed sliding gear with spring.

-
Heat 1st inner race for ball bearing for input shaft to approx. 100 C, fit
onto input shaft and drive onto stop; ensure there is no play. - Check 5th speed sliding gear for axial clearance.
Permissible axial clearance: 0.15-0.35 mm
- Insert dowel sleeves into bearing plate.
- Fit new gasket for end cover.
Pa
ge 30 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-83


- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear), do
this by moving two selector plates (arrows).
- Tighten multi-point socket head bolt to 150 Nm.

- Unclip cover -3- for oil collector from oil collector -1- at longer end with
a screwdriver and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
Pa
ge 32 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5