AUDI A6 1999 C5 / 2.G 01E Transmission Housing Service Workshop Manual

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Transmission housing,
servicing

Special tools, testers and auxiliary items
required:

Multi-purpose tool 771/1 with attachment
771/15
Mandrel 2062
Press tool VW 408 A
Tube VW 423
Thrust pad VW 454
Extractor lever VW 681
Guide pin 10-15
Drift sleeve 30-100
Mandrel 30-505
Installing tool 40-503
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Internal puller 14.5-18.5 mm e.g. Kukko 21/2
Internal puller 30-37 mm e.g. Kukko 21/5
Depth gauge
Assembly sleeve, Part No. 01E 311 120
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Note:

Refer to general repair instructions Page 00
-
11
.
Adjustments are required when replacing
components marked 1) Page 39
-37
,
adjustment overview.
1 -
Seal
For drive flangePulling out Fig. 1Driving in Fig. 2Fill space between sealing lips with sealing
grease G52 128 A1. Replacing with transmission installed
Page 39
-1
2 -
Final drive cover
1)
3 -
O-ring
For cover for final driveAlways replace
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4 -
Shim "S1"
Note thicknessAdjustment overview Page 39
-37
5 -
Outer race for large tapered roller bearing
1) For differentialDriving out and driving in Page 39
-32
6 -
Outer race for small tapered roller bearing
1) For differentialDriving out and driving in Page 39
-31
7 -
Shim "S2"
Note thicknessAdjustment overview Page 39
-37Pa
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8 -
Seal
For input shaftPrying out Fig. 3Driving in Fig. 5Always replace when removing input shaftReplacing when transmission is not
disassembled Fig. 4
and Fig. 5

9 -
Oil drain plug, 40 Nm
10 -
Ball sleeve
For selector shaftReplacePulling out Fig. 6Driving in Fig. 7
11 -
Ball sleeves
For selector shaftsReplacePulling out, as - 10 - Fig. 6Driving in, as - 10 - Fig. 7
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12 -
Circlip
Installation position: eyes facing up
13 -
Switch for back-up lights, 20 Nm
14 -
O-ring For cover for selector shaftAlways replace
15 -
Cover for selector shaft Removing Page 34
-59
Installing Page 34
-85
16 -
Ball stud, 20 Nm
For connecting rod
17 -
Outer race for large tapered roller bearing
1) For drive pinionPulling out Fig. 1 , Page 35
-22
Pressing in Fig. 2 , Page 35
-22
and
Fig. 3 , Page 35
-23

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18 -
Circlip
Removing Fig. 16
19 -
Shim "S3"
Note thicknessAdjustment overview Page 39
-37
20 -
Needle bearing
For input shaftPulling out Fig. 13Driving in Fig. 14Measuring insertion depth Fig. 15
21 -
Locking bolt
For selector shaftRemoving Page 34
-59
Installing Page 34
-85
Tightening torques: For aluminium bolt =
50 Nm, and for steel bolt = 70 Nm
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22 -
Breather
Clip cap onFor transmission with sleeve insertion
depth of sleeve Fig. 11

For transmission with with additional
breather hose Fig. 12

23 -
Trunnion bolt, 40 Nm
For push rod
24 -
Seal for selector shaft Can be replaced when transmission is
removed but not disassembled Always replacePulling out Fig. 8Driving in Fig. 9Always use assembly sleeve for installing
Fig. 10

25 -
Transmission housing
1)
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26 -
Magnet
CleanWhen replacing transmission housing drive
in with e.g. press tool VW 408 A
27 -
Sender for speedometer -G22- Replacing Page 39
-4
28 -
O-ring
Always replace
29 -
Oil filler plug, 40 Nm
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34-135


Note: Fig. 1 Pulling out seal for drive flange
Illustrated, removing oil seal on right-hand side.Procedure for removing oil seal on left and right-hand sides is
identical.

Note: Fig. 2 Driving in seal for drive flange
- Fill space between sealing lip and dust lip with sealing grease G52 128
A1.
Pressing-in depth (factory): 5.5 mmPressing-in depth when re-installing a used drive flange (repairs): 6.5
mm Illustrated, installing oil seal on right-hand side.Procedure for installing oil seal on left and right-hand sides is identical.
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