AUDI A4 2000 B5 / 1.G 01W Transmission Remove And Install User Guide

34-28

All models

Note:
When lowering the transmission, make sure the hydraulic line/hose to
clutch slave cylinder is not damaged. - Remove remaining engine/transmission mounting bolts (arrows -A- and
-B-).
- Press transmission off dowel sleeves and lower carefully using
VAG1383A transmission jack just far enough for access to slave
cylinder.

Note:
After removing the clutch slave cylinder, do not operate the clutch pedal.
Note:
Make sure drive axles have sufficient clearance when lowering
transmission. - Remove clutch slave cylinder (arrow) and secure using wire; do not
disconnect line.
- Lower transmission completely.
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34-29

Securing transmission to assembly
stand


Special tools and equipment

VW309 holding plate
VW353 transmission support

- Secure transmission to assembly stand using VW353 transmission
support and VW309 holding plate when working on transmission.
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34-30

Transmission, transporting


Special tools and equipment

3282 transmission support
3336 transmission support jig
The transmission support jig can be used when
transporting the transmission and for setting up
3282 transmission support.

- Bolt 3336 transmission support jig to transmission housing.

- Adjust support jig on sliding piece using locking pin (arrow).
Number of visible holes = 17
- Lift transmission using workshop crane and 3336 transmission support
jig.
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34-31

Installing

Installation is the reverse order of removal, note
the following:

- Clean input shaft splines and (in case of used
clutch plates) hub splines. Remove corrosion
and apply only a very thin coating of lubricant G
000 100 on splines. Do not grease guide sleeve.

- Check throwout bearing for wear and replace if
necessary.

- Before installing, coat contact surface of clutch
release lever plunger with thin layer of copper
grease, e.g. Z 381 351 TE.

- Threaded holes for mounting clutch slave
cylinder to transmission and shift lever to shift
rod must be cleaned of locking compound
residue using threaded tap before installation.

- Make sure centering sleeves for engine to
transmission are installed correctly in cylinder
block. Install or replace if necessary.

- Always replace self-locking nuts.

-
Install engine/transmission intermediate plate (if
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present) onto engine centering sleeves.

- Make sure intermediate plate is correctly seated
on engine.
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34-32


Repair Manual, Electrical Equipment, Repair Group 27

Repair Manual, Engine Mechanical, Repair Group 26
Radio Operating Manual - Lift transmission until clutch slave cylinder with mounting bracket for
line/hose can be installed (arrow).
- Install lower engine/transmission and starter mounting bolts and install
starter.
- Check adjustment of shift mechanism and adjust if necessary Page
34
-12
.
- Align exhaust system free of stress.- Check transmission oil level Page 34
-36
.
- After connecting battery, enter anti-theft code for radio.- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least a second to
activate automatic window raising/lowering.
- Set clock to correct time.
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34-33

Tightening torques

Transmission to engine (4-cylinder)
A: Dowel sleeves Item No.
Bolt
Tightening torque
1, 3, 4 M12 x 67 65 Nm (48 ft lb)
2, 6 M12 x 90 65 Nm (48 ft lb)
5, 11 M12 x 110 65 Nm (48 ft lb)
7 - 10 M10 x 45 45 Nm (33 ft lb)

Transmission/engine assembly mount (4-cylinder) Item No.
Bolt
Qty.
Tightening torque
1 M10 x 30 3 40 Nm (30 ft lb)
2 M10 x 35 1 50 Nm (37 ft lb)
3 M8 x 20 2 23 Nm (17 ft lb)
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34-34


Transmission to engine (6-cylinder)
A: Dowel sleeves Item No.
Bolt
Qty.
Tightening torque
1 M12 x 67 3 65 Nm (48 ft lb)
2 M12 x 90 1 65 Nm (48 ft lb)
3 M12 x 80 1 65 Nm (48 ft lb)
4 M10 x 45 3 45 Nm (33 ft lb)
5 M10 x 135 1 45 Nm (33 ft lb)
51) M12 x 130 1 65 Nm (48 ft lb) 1) Upper starter bolt

Transmission/engine assembly mount (6-cylinder) Item No.
Bolt
Qty.
Tightening torque
1 M10 x 35 3 40 Nm (30 ft lb)
2 M8 x 20 2 23 Nm (17 ft lb)
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34-35

Component

Tightening
torque
Drive axle to flange
shaft M8 40 Nm (30 ft
lb)

M10 77 Nm (57 ft
lb)
Engine Speed (RPM) sensor -
G28- 10 Nm (7 ft
lb)
Clutch slave cylinder to
transmission
Socket-head bolt 1) 20 Nm (15 ft
lb)
Bolt 2) 25 Nm (18 ft
lb)
Heat shields over drive axles to
transmission 23 Nm (17 ft
lb)

Shift rod to transmission 1) 20 Nm (15 ft
lb)
Pivot rod to transmission 40 Nm (30 ft
lb)
Three Way Catalytic Converter
(TWC) to mounts 25 Nm (18 ft
lb)
Front exhaust pipe to
turbocharger or exhaust 25 Nm (18 ft
lb)
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manifold
Clamp for exhaust pipe 40 Nm (30 ft
lb)
Bracket for noise insulation panel
to body 10 Nm (7 ft
lb)


1) Always replace bolt.
2) Coat with locking fluid D 185 400 A2 before
installing.
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