transmission oil AUDI A6 1999 C5 / 2.G 01E Transmission Repair Instruction Workshop Manual

00-11


Repair instructions
The maximum possible care and cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also, naturally apply
when carrying out vehicle repairs.
A number of generally applicable instructions for
individual repair operations, which are otherwise
mentioned at various points in the Repair
Manual, are summarized here. They apply to this
Repair Manual.

Special tools
For a complete list of special tools used in this
Repair Manual

Special Tools Catalog
Transmission

When installing a replacement transmission or
rear final drive, check oil level and top-up if
necessary Page 34
-39
and Page 39
-80
.

Vehicles with 2.7 ltr 195 kW engine:
replacement transmissions contain an
additional 0.3 ltr of oil for the lines of the
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transmission oil cooling circuit. For this reason
the transmission oil lines and oil cooler must be
drained when fitting a replacement
transmission.
Capacities and specifications from Page 00
-
3 and Page 00
-6 .
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00-12

Thoroughly clean all connections and the
surrounding area before disconnecting.
When installing transmission, ensure dowel
sleeves are correctly seated.

O-rings, seals, gaskets
Always replace O-rings, seals and gaskets.
After removing gaskets and seals, always
inspect the contact surface on the housing or
shaft for burrs resulting from removal or for
other signs of damage.
Thoroughly clean housing joint surfaces before
assembling.

Before installing radial shaft oil seals, lightly oil outer edge and fill
space between sealing lips (arrow) with a thin coating of sealing
grease G 052 128 A1. The open side of the oil seals faces toward the side with fluid filling.When replacing oil seals, always vary the point at which the sealing
lips make contact (use insertion depth tolerances). Lightly oil O-rings before installing; this prevents the rings being
crushed when inserting. Check oil level after replacing gaskets and oil seals Page 34
-39

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Bearings

Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing
towards the drift or other tool used for installing.
Mark needle bearings of 1st to 6th speed sliding
gears when removing, this ensures that when
installing, the same installation position can be
guaranteed.
Grease needle bearing for transmission input
shaft in rear of flywheel.
Lubricate all bearings in transmission housing
with gear oil before installing.
Heat inner races of tapered roller bearings to
approx. 100 C before installing. Press in onto
stop when installing so there is no axial
clearance.

Do not interchange the outer or inner races of
bearings of the same size.
Always replace the tapered roller bearings on
one shaft together and use new bearings from a
single manufacturer.
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The tapered roller bearings for the output shaft
and the differential in the transmission are low-
friction bearings. Do not additionally oil new
tapered roller bearings when measuring friction
torque. The bearings are pre-treated at the
factory with a special type of oil for this
purpose.
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00-17

Synchronizer rings

Do not interchange synchronizer rings. When
reusing always fit to the same gear.
Check for wear, replace if necessary.
Lubricate with gear oil before installing.

Clutch mechanism
When removing transmission, remove clutch
slave cylinder without disconnecting lines.
If the slave cylinder is removed with the
hydraulic line attached, do not depress clutch
pedal. Otherwise the piston will be pressed out
of the slave cylinder.
Ensure that the pressure plate is kept straight:
loosen and tighten bolts in a diagonal sequence
and in several gradual stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the clutch bellhousing, the
flywheel and the parts of the engine facing the
transmission.

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