AUDI A6 2000 C5 / 2.G 01E Transmission End Cover Service Workshop Manual

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End cover, servicing

Special tools, testers and auxiliary items
required:

Thrust plate VW 401
Press tool VW 407
Press tool VW 412
Tube VW 415a
Spacer sleeve VW 472/2
Thrust ring 2006A
Internal puller 37-46 mm (e.g. Kukko 21/6)
Internal puller 46-58 mm (e.g. Kukko 21/7)
Counter support (e.g. Kukko 22/2)
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1 -
End cover
If replaced:
- Re-determine thickness of circlip - 5 -.
- Re-determine shims for Torsen
differential Page 34
-85
.
2 -
Oil drain plug, 40 Nm
3 -
Cylinder roller bearing for input shaft
Pulling out Fig. 1Pressing in flush Fig. 2
4 -
Ball bearing for input shaft
Removing Fig. 3Installing Fig. 4If replaced, re-determine thickness of
circlip - 5 -
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5 -
Circlip
Re-determine thickness Page 34
-108
Installing Fig. 4
6 -
Baffle plate
ReplaceRemoving Fig. 3Installing and peening in position when
replacing ball bearing for input shaft Fig. 5 Installing and peening in position when
replacing end cover Fig. 6

7 -
Needle bearing for Torsen differential
Pulling out Fig. 7 Driving in Fig. 8
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Fig. 1 Pulling cylinder roller bearing for input shaft out of end
cover
A - Internal puller 37-46 mm, e.g. Kukko 21/6
B - Spindle from counter support Kukko 22/2

Fig. 2 Pressing cylinder roller bearing for input shaft flush into
end cover
Tube VW 415a with shoulder towards press tool VW 412
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Fig. 3 Removing ball bearing for input shaft from end cover
- Position screwdriver as illustrated, drive into baffle plate (arrow) and
pry out.
- Remove circlip.
- Take out bearing, remove peening indentations if necessary.

Installation position of circlip:
Note:
The thickness of the circlip must be re-determined if the bearing or the
end cover are replaced. Fig. 4 Installing ball bearing for input shaft in end cover
Ends of circlip (arrows), point towards needle bearing
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- Determine circlip for input shaft ball bearing:

- Press ball bearing outer race onto stop.

- Determine thickest circlip that can still just be
fitted.

Axial play: max. 0.08 mm

- Determine circlip from table. Part numbers

Parts catalog The following circlips are available:

Circlip thickness (mm)
2.55 2.65
2.60 2.70

- Fit circlip.
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Fig. 5 Peening baffle plate in position when replacing ball
bearing for input shaft
- Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen
in position.
- Insert baffle plate.
- Peen at points marked with -arrows 1-.
- Peen at points marked with arrows 2- at distance -a- from first position.

Dimension a = 5 mm
- Observe position and diameter of peening positions:
Dimension b = 2 mm
Dimension c = 3 mm
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Fig. 6 Peening baffle plate in position when replacing end cover
- Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen
in position.
- Insert baffle plate.
- Peen in first peening point (arrow) at distance -d- from center line of
two shafts.

Dimension d = 10 mm
- Observe position and diameter of peening positions.
Dimension b = 2 mm
Dimension c = 3 mm
- Peen in second and third peening points in same manner at distance -
a-.
Dimension a = 70 mm
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Fig. 7 Pulling needle bearing for Torsen differential out from end
cover
A - Internal puller 46-58 mm, e.g. Kukko 21/7
B - Spindle from counter support Kukko 22/2

Fig. 8 Driving needle bearing for Torsen differential flush into
end cover
- Fit press plate VW 412 onto bearing with shoulder facing up.
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