AUDI S4 1996 B5 / 1.G 01E Transmission Repair Instruction Workshop Manual

00-11


Repair instructions
The maximum possible care and cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also, naturally 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
For a complete list of special tools used in this
Repair Manual

Special Tools Catalog
Transmission

When installing a replacement transmission or
rear final drive, check oil level and top-up if
necessary Page 34
-39
and Page 39
-80
.

Vehicles with 2.7 ltr 195 kW engine:
replacement transmissions contain an
additional 0.3 ltr of oil for the lines of the
Pa
ge 1 of 12 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.TM03.00.5

transmission oil cooling circuit. For this reason
the transmission oil lines and oil cooler must be
drained when fitting a replacement
transmission.
Capacities and specifications from Page 00
-
3 and Page 00
-6 .
Pa
ge 2 of 12 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.TM03.00.5

00-12

Thoroughly clean all connections and the
surrounding area before disconnecting.
When installing transmission, ensure dowel
sleeves are correctly seated.

O-rings, seals, gaskets
Always replace O-rings, seals and gaskets.
After removing gaskets and seals, always
inspect the contact surface 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 oil seals, lightly oil outer edge and fill
space between sealing lips (arrow) with a thin coating of sealing
grease G 052 128 A1. The open side of the oil seals faces toward the side with fluid filling.When replacing oil seals, always vary the point at which the sealing
lips make contact (use insertion depth tolerances). Lightly oil O-rings before installing; this prevents the rings being
crushed when inserting. Check oil level after replacing gaskets and oil seals Page 34
-39

Pa
ge 3 of 12 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.TM03.00.5

and Page 39
-80
.
Pa
ge 4 of 12 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.TM03.00.5

00-13

Sealants

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

Locking elements
Do not overstretch circlips.
Always replace circlips which have been
damaged or over-tensioned.
Circlips must be properly seated in the base of
the groove.

Replace spring pins. Position: slit -A- should be in line with the line of
force (arrow).
Pa
ge 5 of 12 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.TM03.00.5

00-14

Nuts, bolts

Loosen nuts or bolts, opposite to tightening
sequence.
Tighten and loosen bolts and nuts for securing
covers and housings in a diagonal sequence.
Especially delicate parts, such as clutch
pressure plates, must not be distorted. Loosen
and tighten bolts and nuts in stages in a
diagonal sequence.
The tightening torques stated apply to non-oiled
nuts and bolts.
Replace self-locking bolts and nuts.
The threads of bolts which are secured by a
locking fluid should be cleaned with a wire
brush. Then apply AMV 185 101 A1 when
inserting.
Threaded holes into which self-locking bolts or
bolts coated with locking fluid are screwed,
must be cleaned (e.g. tap). Otherwise there is a
danger of bolts shearing when subsequently
being removed.
Pa
ge 6 of 12 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.TM03.00.5

00-15

Bearings

Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing
towards the drift or other tool used for installing.
Mark needle bearings of 1st to 6th speed sliding
gears when removing, this ensures that when
installing, the same installation position can be
guaranteed.
Grease needle bearing for transmission input
shaft in rear of flywheel.
Lubricate all bearings in transmission housing
with gear oil before installing.
Heat inner races of tapered roller bearings to
approx. 100 C before installing. Press in onto
stop when installing so there is no axial
clearance.

Do not interchange the outer or inner races of
bearings of the same size.
Always replace the tapered roller bearings on
one shaft together and use new bearings from a
single manufacturer.
Pa
ge 7 of 12 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.TM03.00.5

The tapered roller bearings for the output shaft
and the differential in the 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 8 of 12 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.TM03.00.5

00-16

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 damage.
Only install perfect, undamaged shims.

Gears, synchro-hubs, inner races for sliding
gears
Heat gears and synchro-hubs to approx. 100
C before installing. Press in onto stop when
installing so there is no axial clearance.

Heat inner races for sliding gears to approx.
100 C when installing.

The temperature can be checked with
Temperature tester V.A.G 1558.
Observe installation position.

Sliding gears
Pa
ge 9 of 12 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.TM03.00.5

After installing, check 1st to 6th speed sliding
gears for axial clearance of 0.15-0.35 mm and
check that they rotate freely.
Pa
ge 10 of 12 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.TM03.00.5