AUDI A6 1995 C5 / 2.G 01E Transmission Bearing House And Torsen Differential User Guide

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.
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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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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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e=re
pair&id=AUDI.B5.TM03.34.5

34-65

- Separate bearing plate with input shaft, with
drive pinion and hollow shaft and with inner
selector mechanism from transmission housing.

- Remove circlip from selector rod for 1st and 2nd gear and take off
follower -A-.
- Pull out selector rod -B- for 5th and 6th gear.
- Remove follower -C- for reverse gear.

- Pull thrust washer (arrow -A-) for needle bearing for 6th gear off shaft.
- Use right-angled circlip pliers to remove circlip (arrow -B-) for inner
race for cylinder roller bearing.
- Take out inner race (arrow -C-) for cylinder roller bearing (not a press
fit).
Pa
ge 13 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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pair&id=AUDI.B5.TM03.34.5

34-66


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

Removing and installing reverse gear Page 34
-114
. - Unscrew hex bolt -D-, take off spring clasp -B- and retaining plate -A-,
pull out shaft -C- for reverse idler gear.
- Take out spring, synchro-ring and reverse idler gear.
- Take off relay lever for reverse gear.
Pa
ge 14 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

34-67

Note:

Drive pinion and hollow shaft can be removed
complete if the 6th speed gear can be easily
pried off.
If it is necessary to press off the 6th speed
gear, the drive pinion must be pulled out of the
hollow shaft.

- Remove drive pinion circlip.

Note:
Carefully protect bearings from dirt, clean if necessary. - Pull drive pinion out of hollow shaft -D-, when doing this catch tapered
rollers -A- (Qty. 23).
- Take off corrugated spring -B- and needle ring -C-.
Pa
ge 15 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
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play?action=Goto&t
yp
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pair&id=AUDI.B5.TM03.34.5

34-68


- Check bearing to ensure it is complete:
1 - Flange ring (tapered contact surface to tapered rollers)
2 - Tapered rollers (Qty. 23) with larger diameter facing towards drive
pinion head
3 - Support ring (tapered contact surface to tapered rollers)
4 - Corrugated spring
5 - Circlip for tapered roller bearing for drive pinion

Note:
Because of the type of fit, it may be possible to press gear off easily. - Press off 6th speed gear.
- Take hollow shaft or drive pinion and hollow shaft with selector rod and
selector fork for 1st and 2nd gear out of bearing plate.
Pa
ge 16 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

34-69

Installing

- Fit hollow shaft with selector fork and selector
rod for 1st and 2nd gear (without follower) into
bearing plate.

-
Heat 6th gear to approx. 120 C and fit on. Installation position: shoulder towards tapered roller bearing
- Press onto stop; ensure there is no play.
- Grease drive pinion/hollow shaft tapered roller bearing with multi-
purpose grease before inserting.
Allocation Page 34
-68


A - Flange ring, tapered rollers (Qty. 23), and support ring
B - Corrugated spring
C - Needle ring
D - Hollow shaft
- Oil needle bearing well.
Pa
ge 17 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

- Insert drive pinion into hollow shaft and secure with hose clip to prevent
it slipping out.
Pa
ge 18 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

34-70


- 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