AUDI S4 1997 B5 / 1.G 01E Transmission Assembly Workshop Manual

34-40


Transmission, disassembling
and assembling Assembly sequence Page 34
-54
.
1 -
Bearing housing, Torsen differential and
end cover
Removing and installing Page 34
-41
2 -
Gear cluster and selector shaft
Removing and installing Page 34
-44
3 -
Differential
Removing and installing Page 39
-15
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34-41


Bearing housing, Torsen differential and
end cover, removing and installing

1 -
Bearing housing
Disassembling and assembling Page 34
-89

2 -
Bolt, 25 Nm
Qty. 6
3 -
Dished spring Installation position: larger diameter
(concave side) faces shims
4 -
Shim Qty. 2 or 3Re-determining shims Page 34
-85
5 -
Oil collector
Disassembling and assembling Page 34
-83

Removing Page 34
-58
Installing Page 34
-84
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34-42


6 -
Multi-point socket head bolt, 150 Nm
Removing Page 34
-60
Installing Page 34
-83
7 -
2nd inner race for tapered roller bearing
for input shaft
Removing Page 34
-61
Installing Page 34
-82
8 -
Spring
9 -
Torsen differential
Can be serviced only by manufacturerServicing bearings for Torsen differential
Page 34
-97

10 -
Bolt, 25 Nm
Qty. 5
11 -
End cover Servicing Page 34
-97
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34-43


12 -
Gasket
Replace
13 -
Dowel sleeve Qty. 2
14 -
Gear cluster Removing and installing Page 34
-18
15 -
Oil drain plug - 40 Nm
16 -
Magnet
Qty. 2Clean
17 -
Support plate Installation position: lugs face magnets
18 -
Bolt, 25 Nm Qty. 2
Pa
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34-44


Gear cluster and selector shaft, removing
and installing

1 -
5th and 6th gear
Gear cluster remains flanged to
transmission housing Removing and installing Page 34
-47
2 -
Bearing plate complete
Removing and installing input shaft, drive
pinion, hollow shaft and internal selector
mechanism Page 34
-51

3 -
Bolt - 25 Nm
Qty. 3Apply sealing paste AMV 188 000 02 when
installing
Pa
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34-45


4 -
Cover for selector shaft
Removing Page 34
-59
Installing Page 34
-85
5 -
Selector shaft complete
Removing Page 34
-59
Installing Page 34
-85
Disassembling and assembling Page 34
-144

6 -
Locking bolt
For aluminium bolt: 50 NmFor steel bolt: 70 NmMark installation positions of aluminium
bolts and steel bolts; do not interchange
7 -
Transmission housing Servicing Page 34
-127
8 -
Oil filler plug, 40 Nm
Pa
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34-46


9 -
Differential
Removing and installing Page 39
-15
10 -
Oil drain plug, 40 Nm
11 -
Dowel sleeves
Qty. 2
12 -
Bolt, 25 Nm Qty. 12
Pa
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g and assemblin
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34-47


5th and 6th gear, removing and installing

1 -
1st inner race for tapered roller bearing
for input shaft
Pulling off Page 34
-61
Installing Page 34
-81
2 -
Needle bearing for 5th gear
3 -
Inner race for 5th speed sliding gear
Pulling off Page 34
-64
Driving on Page 34
-81
4 -
5th speed sliding gear
Pulling off Page 34
-61
Installing Page 34
-81
5 -
Roll pin
Pressing out Page 34
-62
Pressing in Page 34
-77
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34-48


6 -
Follower
Only replace complete with selector rod for
5th and 6th gear - 8 - Pulling off Page 34
-63
Fitting Page 34
-77
7 -
Selector fork for 5th and 6th gear
Can be replaced individually
8 -
Selector rod for 5th and 6th gear Only replace complete with follower - 6 -Removing Page 34
-62
Installing Page 34
-72
9 -
Locking collar, synchro-ring, synchro-hub
for 5th and 6th gear
Removing Page 34
-63
Installing Page 34
-76
Pa
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34-49


10 -
Circlip
Re-determining Page 34
-80
11 -
5th speed gear
Pulling off Page 34
-62
Pressing on Page 34
-79
12 -
6th speed sliding gear
Pull off together with synchro-hub and
inner race for 5th gear Page 34
-64

13 -
Needle bearing for 6th gear
14 -
Thrust washer for needle bearing for 6th
gear
Installation position: grooves face circlip,
smooth face contact surface towards
needle bearing
15 -
Circlip
Pa
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