differential AUDI A6 1999 C5 / 2.G 01E Transmission Bearing House And Torsen Differential Owner's Manual

34-72


- Slide inner race (arrow -C-) for cylinder roller bearing onto main shaft at
flange for end cover (clearance fit).
- Fit circlip (arrow -B-) using right-angled circlip pliers.

- Engage recess in follower for reverse gear with the free end of relay
lever (arrow -A-).
- Slide selector rod for 5th and 6th through follower for reverse gear in
direction of (arrow -B-).
Pa
ge 21 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-73


- Slide follower -A- for 1st and 2nd gear onto selector rod and secure
with circlips.
- Oil all bearings of input shaft and drive pinion/hollow shaft in
transmission housing and bearing flange as well as selector rods with
gear oil.

Note:
When inserting the complete bearing plate, ensure that the selector rods
align with their mounting points. - Pry used seal for input shaft carefully out of transmission housing with
VW 681.
- Coat sealing surfaces between bearing plate and transmission housing
with sealing paste AMV 188 000 02 or AMV 188 001 02 sealing paste.
- Insert complete bearing plate into transmission housing.
Pa
ge 22 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-74

- Drive in 2 dowel sleeves for bearing
flange/transmission housing.

- Tighten 12 bolts using diagonal sequence to 25
Nm.

Note: - Screw in locking bolts for selector rods.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
Aluminium and steel bolts must not be interchanged when installing.Tightening torques: for aluminium locking bolts = 50 Nm, and for steel
locking bolts = 70 Nm
Pa
ge 23 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-75


- Fit thrust washer (arrow -A-) for needle bearing for 6th speed gear.
Installation position: shoulder towards circlip (arrow -B-), smooth
contact surface to shaft end
- Oil needle bearing for 6th speed sliding gear with gear oil and fit.
- Slide on 6th speed sliding gear with spring and synchro-ring.
Synchro-ring installation position: the lugs of the synchro-ring engage
into the recesses below in the sliding gear

- Support input shaft with support bridge 30-211 A.
Pa
ge 24 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-76


Installation position of synchro-hub for 5th and 6th gear:
Side with projecting face (arrow -1-) faces shaft end The oil drilling of the input shaft (arrow -2-) and the oil groove of the
synchro-hub (arrow -3-) are in line

-
Heat synchro-hub for 5th and 6th gear to approx. 100 C, fit and drive
on; ensure there is no play. - Check 6th speed sliding gear for axial play.
Pa
ge 25 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-77


Note: - Line up markings (arrow -3-) on paired synchro-hub -A- and locking
collar for 5th and 6th gear (arrow -1-).
- Fit locking collar (arrow -1-) with selector fork (arrow -2-) onto synchro-
hub -A- as well as follower for 5th and 6th gear -B- onto selector rod -
C- at the same time.
Selector fork rib (arrow -2-) must face towards shaft end. When sliding follower onto selector rod for 5th and 6th gear remember
holes for roll pin.

Note:
Do not drive in roll pin, otherwise selector rod mounting will be damaged. - Press in roll pin -A- flush.
Pa
ge 26 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-78
Re-determining shim for 5th speed gear:

Parts catalog
The following shims are available: - Fit spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
- When fitting circlip, push in direction of arrow onto stop.
- Measure distance between sleeve and fitted circlip with depth gauge -
B-.
- Determine shim from table.Measured range (mm)
Shim thickness (mm)
31.01-31.11 1.05
31.11-31.21 1.15
31.21-31.31 1.25
31.31-31.41 1.35
Pa
ge 27 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-79


- Fit shim selected (arrow) onto hollow shaft.

-
Heat 5th speed gear to approx. 120 C, fit and drive onto stop free of
play.
Installation position: shoulder toward spacer sleeve
Pa
ge 28 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-80


Re-determining circlip for 5th speed gear:
Parts catalog
The following circlips are available: - Determine thickest circlip that can still just be fitted.
- Determine circlip from table.Circlip thickness (mm)
2.32 2.40 2.48
2.34 2.42 2.50
2.36 2.44
2.38 2.46 - Fit circlip.
Pa
ge 29 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-81


- Drive on inner race for 5th speed sliding gear free of axial play.
- Oil needle bearing with gear oil and fit.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th speed sliding gear with spring.

-
Heat 1st inner race for ball bearing for input shaft to approx. 100 C, fit
onto input shaft and drive onto stop; ensure there is no play. - Check 5th speed sliding gear for axial clearance.
Permissible axial clearance: 0.15-0.35 mm
- Insert dowel sleeves into bearing plate.
- Fit new gasket for end cover.
Pa
ge 30 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5