engine AUDI A4 1997 B5 / 1.G 01A Transmission Remove And Install User Guide

34-32

Installing
Install in 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 very thin coating of lubricant G
000 100 on splines. Do not grease guide sleeve.

- Check clutch release bearing for wear, replace if
necessary.

- Coat contact surface of clutch slave cylinder
pivot rod with thin layer of copper grease, e.g.
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 thread tap before installation .

- Make sure dowel sleeves for aligning
engine/transmission are installed in cylinder
block, install if necessary.

- Always replace self locking nuts.
Pa
ge 16 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2

34-33


- Lift up transmission until clutch slave cylinder with mounting bracket for
line/hose can be installed (arrow).
- Install intermediate plate (if applicable) between transmission and
engine onto appropriate engine dowel sleeves.
- Make sure intermediate plate is correctly positioned on engine.
- Install lower engine/transmission and starter mounting bolts, and install
starter Repair Manual, Electrical Equipment, Repair Group 27

- Before installing, use tap to clean threads in flange shaft for driveshaft
on transmission to remove traces of locking compound.
- Replace gaskets on drive axles and on front of driveshaft Page 39
-
69
.
- Install driveshaft Page 39
-71
.
- Check adjustment of shift rod and pivot rod, re-adjust if necessary
Page 34
-12
.
Pa
ge 17 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2

34-34

- Align exhaust system free of stress.
Repair Manual, Engine Mechanical, Repair
Group 26
- Check transmission oil level Page 34
-38
.

- After
connecting
battery,
enter anti-
theft code
for radio
Repair Manual,
Electrical Equipment, Repair Group 91


- Run power windows fully up by pressing
switches.

- Operate all power window switches again and
hold for at least one second in "close" position to
activate automatic one-touch function.

- Set clock to correct time.
Pa
ge 18 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2

34-35

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)
Pa
ge 19 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2

34-36


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)
Pa
ge 20 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2

34-37

Component Nm ft
lb
Drive axle to flange shaft M8 40 30
Drive axle to flange shaft M10 80 59
Engine speed sensor -G28- 10 7
Clutch slave cylinder to transmission 20 15
Heat shields over drive axles on
transmission 23 17
Shift rod to transmission 23 17
Pivot rod to transmission 40 30
Driveshaft to transmission 55 41
Heat shield for driveshaft to cover of
Torsen differential 25 18
Three Way Catalytic Converter (TWC)
to mounts 25 18
Front exhaust pipe to turbocharger or
exhaust manifold 25 18
Clamp for exhaust pipe 40 30
Bracket for noise insulation panel to
body 25 18
Pa
ge 21 of 21 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.2