oil AUDI A4 1998 B5 / 1.G 01A Transmission General Repair Instructions Workshop Manual

00-14


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

After replacing the transmission or rear final
drive, check oil level and top-up if necessary
Page 34
-38
and Page 39
-84
.

Capacities and specifications Page 00
-3 and
Page 00
-9 .

Thoroughly clean all connections and the
surrounding area before disconnecting.
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O-rings, gaskets, seals

Always replace O-rings, gaskets and seals.
After removing gaskets and seals, always
inspect the contact surfaces 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 seals, lightly oil outer edge and fill space
between sealing lip and dust lip (arrow) with oil. The open side of the seals face toward the side containing the oil.When replacing seals, always vary the point at which the sealing lips
make contact (use insertion depth tolerances). Lightly lubricate O-rings before installing, this prevents the rings from
being pinched when inserting. Check oil level after replacing gaskets and seals Page 34
-38
or
Page 39
-84
.
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Nuts, bolts

Always replace self-locking nuts and 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 canted. Loosen
and tighten bolts and nuts in stages in a
diagonal sequence.
The tightening torques stated apply to non-oiled
nuts and bolts.
The threads of bolts which are secured by a
locking compound should be cleaned using a
wire brush. Then apply AMV 185 101 A1 when
installing.

CAUTION!
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information.
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Bearings

Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing the
drift or other installation tool.
Grease needle bearing for the input shaft in the
crankshaft.
Lubricate all bearings in transmission with gear
oil before installing.
Always replace tapered roller bearings on one
shaft together and use new bearings from the
same manufacturer.
Heat tapered roller bearing inner races to
approx. 100 C (212 F) before installing. Press
in until stop is reached so there is no axial play.

Do not interchange inner and outer bearing
races with those from other bearings of the
same size.
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
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factory with a special type of oil for this
purpose.
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Synchronizer rings

Do not interchange.
When re-using, install synchronizer rings with
the same gear with which they were previously
matched.
Check for signs of wear; replace if necessary.
Lubricate with gear oil before installing.

Clutch mechanism
When removing transmission, remove clutch
slave cylinder without opening hydraulic lines.

CAUTION!

Do not depress the clutch pedal after
removing the slave cylinder. Otherwise the
piston will be pressed out of the slave
cylinder.
Do not cant clutch pressure plate, loosen and
tighten in a diagonal sequence and in stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the bellhousing, flywheel and
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