4WD AUDI A6 2000 C5 / 2.G Changing Clutch 5Speed Manual Gearbox

Removing gearbox Installing
Installation is carried out in the reverse order; note the following:
‒ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Do not grease guide sleeve. It should be possible to push the clutch
plate back and forth slightly.
‒ Check clutch release bearing for
wear, replace if necessary.
‒ → If the plastic ring of the release
bearing is loose, it must be bonded
back onto the bearing ring with
adhesive AMV 195 KD1 01.
Three rectangular lugs -arrows- on the plastic ring engage into recesses in the bearing ring.
If any score marks deeper than 0.5 are present, the bearing ring must be replaced.
‒ Lightly lubricate contact surface for
push rod at clutch release lever with
copper grease, e.g. Z 381 351 TE.
‒ All threaded holes in which self-locking bolts are to be screwed must be cleaned of residual locking
compound using a thread tap.
‒ Check whether the dowel sleeves for centralising engine/gearbox are in
the cylinder block; install if
necessary. ‒ Renew all self locking nuts.
‒ If fitted, ensure that the intermediate
plate is correctly positioned on the
engine.
‒ → Lift gearbox until clutch slave
cylinder with bracket for hose/pipe
can be installed (arrow).
Note:
Carefully press the clutch pedal after the
slave cylinder has been installed. If an
unusually hard pressure point is noticeable when the pedal is pressed, the clutch pedal must not be pressed any further. The
tappet of the slave cylinder has probably
been moved past the clutch release lever.
The slave cylinder will be destroyed with a pedal force of approx. 300 N and above. Page 1 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

‒ Install lower engine/gearbox securing bolts and bolts for starter. For this
purpose, insert the starter.
=> Electrical System; Repair group 27; Removing and installing starter
‒ Bolt drive shafts to flange shafts.
=> Running Gear, FWD and 4WD; Repair group 40
‒ The threaded bores in the flange
shaft of the manual gearbox for the
propshaft must be cleaned of
remaining locking fluid with a thread
tap before assembling
‒ Replace front gaskets at propshaft
=> Page 39-79 and at drive shafts.
‒ Attaching propshaft => Page 39-84.
‒ Check selector rod and push rod,
adjust if necessary => Page 34-11.
‒ Tension free alignment of exhaust
system
=> 4-cylinder Engine (5-valve turbo), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
=> 6-cylinder Engine (5-valve), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
‒ Check oil level in manual gearbox => Page 34-56.
‒ Electrical connections and routing:
=> Current Flow Diagrams, Electrical Fault-
finding and Fitting Locations binder
‒ Connect the battery.
Notes:
◆ If the battery is reconnected, please
ensure that the vehicle equipment
(radio, radio/navigation system,
clock, electric window lifters) is
activated as described in the
operating instructions.
◆ Deactivate the service mode of the
telematics control unit.
=> Radio, Telephone and Navigation Page 2 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

System; Repair group 91 Tightening torques → Gearbox to engine (4-cylinder)
A: Centring sleeves Item Bolt Nm
1, 3, 4 M12 x 67 65
2, 6 M12 x 90 65
5, 11 M12 x 110 65
7...10 M10 x 45 45 → Gearbox/engine assembly mountings (4-
cylinder)
Item Bolt Qty. Nm
1 M10 x 30 3 40
2 M10 x 35 1 50
3 M8 x 20 2 20 → Gearbox to engine (6-cylinder)
5* = upper starter bolt
A: Centring sleeves Item Bolt Qty. Nm
1 M12 x 67 3 65
2 M12 x 90 1 65
3 M12 x 80 1 65
4 M10 x 45 3 45
5 M10 x 135 1 45
5 * M12 x 130 1 65 Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

→ Gearbox/engine assembly mountings (6-
cylinder) 1) Replace bolt Item Bolt Qty. Nm
1 M10 x 35 3 40
2 M8 x 20 2 20 Component Nm
Engine speed sender -G28 10
Clutch slave cylinder to
gearbox 1) 23
Heat shields over drive
shafts to gearbox 23
Selector joint to gearbox 1) 23
Push rod to gearbox 40
Propshaft to gearbox 55
Heat shield for propshaft to
Torsen differential cover 25
Bracket for noise insulation
to body 10 Page 4 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

Removing and installing cover with Torsen differential Removing and installing cover with Torsen differential
● Gearbox installed
Removing
Vehicles with 4-cylinder engine:
‒ Remove rear section of exhaust system from clamp(s):
=> 4-cylinder Engine (5-valve turbo), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system
Vehicles with 6-cylinder engine:
‒ Unscrew lambda probes on right exhaust pipes with special tool 3337 and move clear to the side. ‒ Detach heat shield above right drive
shafts.
‒ → Unbolt front exhaust pipes with
catalytic converters from left and
right exhaust manifolds (3 nuts on
each side) -arrows-:
=> 6-cylinder Engine (5-valve), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system ‒ → Remove heat shield for propshaft
from cover for Torsen differential -
arrows-. ‒ → Unscrew propshaft -1- from Page 1 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141331.xml?xsl=2

gearbox and place onto heat shield -2-. ‒ Secure propshaft with wire -arrow- at bracket -3- of fuel lines.
‒ Place drip tray underneath.
‒ Drain gear oil. ‒ → Unbolt cover -A- with Torsen
differential from gearbox cover -B-.
Note:
Shown in illustration with gearbox removed. ‒ Detach spring -C- from drive pinion.
Installing
Installation is carried out in the reverse
order; note the following:
‒ Remove old sealing paste and clean
the sealing surfaces thoroughly.
‒ Apply sealing paste AMV 188 001 02 to sealing surfaces. ‒ → Check that compression spring -
C- is fitted and that dowel sleeves -
arrows- are fitted in gearbox cover -
B- or in cover -A-.
‒ Fit cover -A- and tighten.
‒ Attaching propshaft => Page 39-84.
‒ Top up oil in gearbox and check oil
level in gearbox => Page 34-56.
‒ Tension free alignment of exhaust
system
=> 4-cylinder Engine (5-valve turbo), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
=> 6-cylinder Engine (5-valve), Mechanical Page 2 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141331.xml?xsl=2

Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
Tightening torque
Component Nm
Cover with Torsen differential to
gearbox 25
Propshaft to gearbox 55
Heat shield for propshaft to
Torsen differential cover 25
Heat shields over the right-
hand drive shaft to gearbox (for
6-cylinder engine only) 23 Page 3 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141331.xml?xsl=2

Dismantling and assembling gearbox Removing and installing input shaft ball bearing and multi-function sender 1.Gearbox housing ◆ With differential and flange shafts
◆ Removing and
installing
flange
shafts=> Page
39-1
◆ Removing and
installing
differential =>
Page 39-18
◆ Removing and
installing
speedometer
sender and
drive wheel =>
Page 39-15
◆ Breather
installation
position =>
Fig.1
◆ Apply thin coat of sealing
paste AMV
188 001 02 to
sealing
surfaces
2.Torx socket head
bolt - 35 Nm
◆ Self-locking
◆ Replacing
3.Guide sleeve ◆ With O-ring
and seal for
input shaft =>
Page 30-32
◆ Pack sealing
ring between
sealing and
dust lips half-full with sealing grease G 052
128 A1.
4.Dished washer
◆ Smaller
diameter
(convex side) to guide sleeve 5.Circlip
◆ Determining
thickness => Adjusting input shaft, Page 35-23 Page 1 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141335.xml?xsl=2

6.Ball bearing ◆ Removing and installing=>Page 34-74
7.Circlip
◆ Determining
thickness =>
Adjusting input
shaft, Page 35-23 8.Drive shaft ◆ Removing and installing=>Page 34-69
◆ Dismantling and assembling =>
Page 35-1
◆ Adjusting =>
Page 35-23
◆ Servicing input
shaft bearings
=> Page 35-1
9.Bolt - 25 Nm
10.Locking plate
◆ For multi-
function sender
11.Multi-function sender 12.Connector for multi-
function sender
13.Bolt - 10 Nm
14.Cover for selector
shaft
◆ Removing and installing=>Page 34-98
15.Locking unit for 5th gear and reverse gear Page 2 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141335.xml?xsl=2

◆ Removing and installing=>Page 34-105 → Fig.1 Breather installation position After pressing in, the breather must project 21 mm
out of housing. Page 3 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141335.xml?xsl=2