AUDI A4 2000 B5 / 1.G 01A Transmission General Repair Instructions User Guide

00-20

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 signs of damage.
Only install shims that are in perfect
condition.

Gears, synchro-hubs, inner races for sliding
gears
Heat gears and synchro-hubs to approx. 100
C (212 F) before installing. Press in until stop
is reached so there is no axial play.

Heat inner races for sliding gears to approx.
100 C (212 F) when installing.

The temperature can be checked using
VAG1558 temperature tester.
Observe installation position.

Sliding gears
Pa
ge 11 of 14 General 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.TM02.00.5

After assembling, check axial play of 1st to 5th
sliding gears and reverse sliding gear (0.15-0.35
mm .006-.014 in.) and check for free movement.
Pa
ge 12 of 14 General 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.TM02.00.5

00-21

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
Pa
ge 13 of 14 General 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.TM02.00.5

the side of the engine facing the transmission.
Pa
ge 14 of 14 General 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.TM02.00.5