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

can be fitted
◆ Follow correct work sequence when bleeding
=> Page 30-30 13.Bleed valve
◆ Tighten to 4.5
Nm
◆ Follow correct work sequence when bleeding
=> Page 30-30 ◆ A broken
bleeder valve
can be
screwed out
with a 3 mm
hexagon
socket wrench 14.Dust cap 15.Securing clip
◆ To remove the
line, pull out
the clamp =>
Fig.1
16.Bracket
◆ Secured to
gearbox
17.Hexagon socket-
head bolt - 23Nm
◆ Slave cylinder
to gearbox
◆ Self-locking
◆ Always replace 18.Nut - 2 Nm
19.Seal Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141311.xml?xsl=2

cylinder. Clip pin onto clutch pedal.
‒ → Press retaining clip -C- home.
‒ Push pipe -B- into master cylinder
until it audibly locks in place.
‒ Insert rubber grommet -D- over
connection pipe/supply hose -A- into
the cross panel.
‒ Push supply hose -A- for the brake
fluid reservoir on to limit stop.
‒ Remove special tool 3094.
‒ After installing the master cylinder,
bleed the clutch system =>Page 30-30.
‒ If fitted, check the adjustment of the
clutch pedal switch -F 36 => Page
30-8.
‒ Install storage compartment for
driver's side: => General Body Assembly, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage compartment Page 6 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

◆ Secure to clutch release lever
9.Torx socket head
bolt - 35 Nm
◆ Self-locking
◆ Replacing
10.Clutch release
lever
◆ Before
installing,
coat contact
surface of
clutch slave
cylinder push
rod with
copper grease, e.g. Z 381 351 TE. 11.Release bearing ◆ With or
without
plastic ring, depending on version
=>Fig.1
◆ Cement
detached plastic ring => Fig.1
◆ Do not wash
out bearing,
only wipe
◆ Replace
noisy
bearings
◆ Engage
retaining
latches at the
release
bearing in
contact
release lever 12.Slave cylinder
◆ Do not Page 2 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

operate clutch
pedal after slave cylinder has been
removed.
◆ Removing => Fig.2
◆ Detach from
hose/pipe
assembly =>
Fig.3
◆ Installing =>
Fig.4 and
Fig.5
◆ When
installing, press in slave cylinder far
enough so
that securing
bolt can be
fitted easily.
◆ Follow
correct work
sequence
when
bleeding =>
Page 30-30
◆ Tighten bleed valve to 4.5
Nm 13.Hexagon socket-head bolt - 23Nm
◆ Slave
cylinder to
gearbox
◆ Self-locking
◆ Always
replace
14.Bracket
◆ For hose/pipe assembly
◆ Attached
together with
the slave cylinder to the gearbox
◆ Installing =>
Fig.5
15.Push rod
◆ Lubricate end of push rod
with copper grease, e.g. Z 381 351 TE Page 3 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

Servicing gear selector mechanism for vehicles up to 05.99 Checking gear stick position
● The gear stick must rest in the 3rd/4th gear gate when the gearbox is in neutral.
‒ Depress clutch.
‒ Check that all gears can be engaged.
‒ Check operation of reverse gear lock.
‒ The gear stick should return by itself from the 5th/reverse gear gate into the 3rd/4th gear gate.
‒ Check fine adjustment if necessary. Fine adjustment ‒ → Loosen ball housing nuts -arrow
A- and -arrow B-.
‒ Push gear stick to the right, up to
gearbox stop.
‒ For this purpose, push the ball
housing to the left against the gear
stick.
‒ Then hold gear stick and ball
housing in this position and tighten.
‒ Fit covers and gear stick knob.
Note:
If only 5th and reverse gear cannot be
engaged, the 5th and reverse gear locking
unit should be checked and replaced if necessary =>Page 34-105. Page 1 of 15-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141319.xml?xsl=2

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

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

(arrows) for the intermediate bearing
and remove the propshaft with the
assembly device.
Note:
Only transport and store propshaft when
extended. Installing Installation is carried out in the reverse
order; note the following:
Notes:
◆ → To avoid imbalance the flanges of the propshaft -arrow A- and of the
rear final drive -arrow B- must be
fitted so that the factory colour
markings or the subsequently made
markings are aligned.
◆ If a new propshaft is installed and if
the factory colour marking on the
flange of the rear final drive is no
longer visible the radial run-out on
the propshaft flange must be
measured => Page 39-87 and the
colour marking on the propshaft
aligned with the new marking on the
flange.
◆ Renew gaskets on flange shafts
(detach protective foil and stick
gasket onto flange shaft).
◆ After removing the propshaft from
the rear final drive, the additional
balance disc (thicker washer) that
may be located between the lock
plate and the bolt head must not be
reinstalled.
◆ It is essential that the locking fluid
remaining in the threads in the
flange shafts on the gearbox and
rear final drive is cleaned out after
removing the propshaft. Otherwise
there is a danger that the new bolts
will seize when they are screwed in
and then shear if they have to be
removed later.
◆ The threaded holes can be cleaned Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141363.xml?xsl=2