AUDI A4 2000 B5 / 1.G 01W Transmission General Repair Instructions Workshop Manual

00-10


General repair instructions
The maximum possible care, cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also apply when
carrying out vehicle repairs.
A number of generally applicable instructions for
individual repair operations, which are otherwise
mentioned at various points in the Repair
Manual, are summarized here. They apply to this
Repair Manual.

Special tools and equipment
For a complete list of special tools and
equipment used in this repair manual "Special
tools catalog."
Transmission

Using parts catalog microfiche, match bolts and
other components according to transmission
codes Page 00
-3 .

After replacing the manual transmission , check
oil level and top-up if necessary Page 34
-36
.

Capacities and specifications Page 00
-3 .

Pa
ge 1 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

Thoroughly clean all connections and the
surrounding area before disconnecting.
When installing transmission, make sure
centering sleeves for aligning engine and
transmission are correctly seated.
Pa
ge 2 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

00-11

Sealants

Thoroughly clean housing joint surfaces before
applying sealant.
Apply sealant AMV 188 000 02 or AMV 188 001
02 evenly and not too thick.
Breather holes must be free of sealant.

O-rings, gaskets, seals
Always replace O-rings, gaskets and seals.
After removing gaskets and seals, always
inspect the contact surfaces on the housing or
shaft for burrs resulting from removal, or for
other signs of damage.
Thoroughly clean housing joint surfaces before
assembling.

Before installing radial shaft seals, lightly oil outer edge and fill space
between sealing lip and dust lip (arrow) with oil. Open side of the seal faces toward the side containing the oil.When replacing seals, always vary the point at which the sealing lips
make contact (use insertion depth tolerances).
Pa
ge 3 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

Lightly lubricate O-rings before installing. This prevents the rings from
being pinched while being inserted. Check transmission oil level after replacing gaskets and seals Page 34
-36
.
Pa
ge 4 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

00-12

Circlips

Do not over-stretch circlips.
Always replace.
Circlips must be fully seated in groove.

Nuts, bolts
Always replace roll pins. Installed position: slot -A- is longitudinal to line of force (arrow).Always replace self-locking nuts and bolts.Loosen nuts or bolts opposite to torque sequence.Tighten and loosen bolts or nuts for securing covers and housings in a
diagonal sequence. The tightening torques stated apply to non-oiled nuts and bolts.The threads of bolts which are secured by a locking compound should
be cleaned using a wire brush. Then apply AMV 185 101 A1 when
installing. Threaded holes for self-locking bolts or bolts coated with locking fluid
must be cleaned with tap. Otherwise there is a danger of bolts
shearing when subsequently being removed.
Pa
ge 5 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

00-13

Bearings

Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing the
drift.
Mark needle bearings of drive gears for first
through fifth sliding gears when removing to
ensure the same installed position when
installing.
Grease needle bearing for input shaft in
flywheel.
Lubricate all bearings in transmission with
transmission fluid before installing.
Heat tapered roller bearing inner races to
approx. 100 C (212 F) before installing. Press
in to stop so that there is no axial play.

Do not interchange inner and outer bearing
races with those from other bearings of the
same size.
Always replace tapered roller bearings on one
shaft together and use new bearings from the
same manufacturer.
Pa
ge 6 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

The tapered roller bearings for the output shaft
and the differential in the manual transmission
are low-friction bearings. Do not additionally oil
new tapered roller bearings when measuring
friction torque. The bearings are pre-treated at
the factory with a special type of oil for this
purpose.
Pa
ge 7 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

00-14

Shims

Use a micrometer to measure the shims at
several points. Different tolerances make it
possible to obtain the exact shim thickness
required.
Check for burrs and signs of damage.

Sliding Gears
After assembling, check axial play of 1st to 5th
sliding gears (0.15-0.35 mm) and check for free
movement.

Synchronizer rings
Do not interchange. When re-using, install
synchronizer rings with the same gear with
which they were matched.
Check for signs of wear; replace if necessary.
Lubricate with transmission fluid before
installing.

Gears, synchro-hubs, inner races for sliding
gears
Pa
ge 8 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

Heat gears and synchro-hubs to approx. 100
C (212 F) before installing. Press into stop so
there is no axial play.

Heat inner races for sliding gears to approx.
100 C (212 F) before installing.

The temperature can be checked using
VAG1558 temperature tester.
Note installation position.
Pa
ge 9 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4

00-15

Clutch mechanism

When removing transmission, remove clutch
slave cylinder without disconnecting lines.
Do not depress the clutch pedal after removing
the slave cylinder if the hydraulic line is still
connected. Otherwise the piston will be pressed
out of the slave cylinder.
Do not cant clutch pressure plate; loosen and
tighten in a diagonal sequence and in stages.
If the clutch has burnt out, thoroughly clean the
bellhousing, flywheel and parts of the engine
facing the transmission in order to reduce the
smell of burnt linings.
Pa
ge 10 of 10 General re
pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4