oil 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
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put shaft, drive
pinion and hollow shaft, removi...
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34-58


- Pull oil collector out of end cover (arrow) until it moves freely.

- Swing oil collector (arrow) down and guide out through hole in end
cover.
- Remove oil collector.
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g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
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34-69

Installing

- Fit hollow shaft with selector fork and selector
rod for 1st and 2nd gear (without follower) into
bearing plate.

-
Heat 6th gear to approx. 120 C and fit on. Installation position: shoulder towards tapered roller bearing
- Press onto stop; ensure there is no play.
- Grease drive pinion/hollow shaft tapered roller bearing with multi-
purpose grease before inserting.
Allocation Page 34
-68


A - Flange ring, tapered rollers (Qty. 23), and support ring
B - Corrugated spring
C - Needle ring
D - Hollow shaft
- Oil needle bearing well.
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g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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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.
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g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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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.
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g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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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.
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ge 25 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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play?action=Goto&t
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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.
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g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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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.
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ge 31 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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play?action=Goto&t
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pair&id=AUDI.B5.TM03.34.5

34-83


- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear), do
this by moving two selector plates (arrows).
- Tighten multi-point socket head bolt to 150 Nm.

- Unclip cover -3- for oil collector from oil collector -1- at longer end with
a screwdriver and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
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g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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34-84


- Guide oil collector from interior of end cover with support arm leading
through hole of end cover (arrow), until O-ring can be fitted from
outside onto oil collector.
- Lightly oil new O-ring and fit.
- Insert oil tube of oil collector into input shaft.

- Turn oil collector until the positioning segment is located in the
machined recess of the end cover (arrow).
- Press in oil collector onto stop.
- Slide assembly sleeve, Part No. 01E 311 120, onto selector shaft.
- Check neutral position of followers.
Selector gates must align.
Pa
ge 33 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