ECU AUDI A6 1999 C5 / 2.G 01E Transmission Bearing House And Torsen Differential Workshop Manual

34-56

Removing

- Secure transmission on engine and transmission support VW 540.
- Place drip tray V.A.G 1306 underneath and drain transmission oil (2 oil
drain plugs).
- Remove release bearing, clutch release lever and guide sleeve
Page 30
-27
.

- Remove bearing housing (arrow) and pull off.
A - M8/M10 stud
Pa
ge 4 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.TM03.34.5

34-60


- Loosen and unscrew multi-point socket head bolt (arrow -B-) in input
shaft through hole (arrow -A-) in end cover.
- Remove 2 securing bolts (arrow -C-) for end cover for transmission at
supporting plate for needle bearings -arrow D-.
- Take out supporting plate.

- Remove 2 magnets (arrows -A-) and clean.
- Loosen 5 bolts (arrows -B-) for securing end cover for transmission and
remove.
Pa
ge 8 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
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

34-64


- Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub
for 5th and 6th speed gears and inner race for 5th speed sliding gear.
A - Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks

- Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Mark fitting locations of aluminium and steel bolts. (Bolts must not be
interchanged when installing.)
- Drive out dowel sleeves on bearing plate and remove bearing plate
from transmission housing.
- Secure drive pinion relative to hollow shaft e.g. hose tie, to prevent it
falling out.
Pa
ge 12 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

- Insert drive pinion into hollow shaft and secure with hose clip to prevent
it slipping out.
Pa
ge 18 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

34-82


Note:
Do not tighten bolts. - Fit end cover and insert securing bolts (arrows -B-).
- Clean two magnets (arrows -A-) and insert.
- Fit support plate and tighten hand tight.

Installation position: Lugs towards magnets
- Tighten bolts for end cover using diagonal sequence.

- Oil 2nd inner race and with ball contact surface facing towards input
shaft ball bearing, drive onto input shaft through hole in end cover.
- Remove support bridge 30-211 A.
Pa
ge 31 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