Repair Instructions

Transmission 

• Thoroughly clean all connections and the surrounding area before disconnecting.
• When installing the transmission, make sure that the alignment sleeves between the engine and transmission are positioned correctly.
• Allocate bolts and other component using the.
• When installing mounting brackets, as well as other waxed components, the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
• After replacement of the manual transmission with a bevel box, check the oil level in the manual transmission. Refer to MANUAL TRANSMISSION, CHECKING GEAR OIL LEVEL and in the bevel box GEAR OIL IN BEVEL BOX, CHECKING .
• Capacities, refer to CODE LETTERS, ASSEMBLY ALLOCATION, RATIOS AND CAPACITIES 

Shaft Seals, Sealing Rings, O-rings, Seals 

• Always replace shaft sealing rings, O-rings, and seals.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with sealing grease G 052 128 A1.
  Fig 1: Identifying Oil Seals Sealing Lips

  Courtesy of AUDI OF AMERICA, LLC
• The open side of the shaft seals point toward the fluid to be sealed in.
• When pressing in new shaft seal, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• To prevent crushing when installing, lightly lubricate O-rings before inserting.
• After replacement of seals, O-rings, and shaft sealing rings, check the oil level in the manual transmission. Refer to MANUAL TRANSMISSION, CHECKING GEAR OIL LEVEL or in the bevel box GEAR OIL IN BEVEL BOX, CHECKING .

Sealant 

• Thoroughly clean housing joint surfaces before applying sealing compounds.
• Apply the sealing compound AMV 188 200 03 evenly and not too thick.
• Do not allow sealing compound to enter ventilation openings.

Fasteners 

• Do not stretch the circlips.
• Replace damaged or stretched circlips.
• Circlips must locate properly in the groove.
• Replace spring pins. Installed position: the slit -A- should be in line with the line of force -arrow-.
  Fig 2: Identifying Locking Elements

  Courtesy of AUDI OF AMERICA, LLC

Bolts and Nuts 

• Loosen bolts and nuts in reverse of tightening sequence.
  Fig 3: Identifying Nut And Bolt

  Courtesy of AUDI OF AMERICA, LLC
• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
• Replace self-locking bolts and nuts.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (for example tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
• Ensure with screwed connections that the contact surfaces as well as the visible surfaces of nuts and bolts are waxed after assembly, if necessary.

Mount 

• Install new tapered roller bearing as supplied and do not use additional oil.
• Install various bearings (removed tapered roller bearings) into transmission, lubricated with gear oil.
• Heat the inner rings of the tapered roller bearings to approximately 100 °C (212 °F) with the inductive heat unit VAS 6414 before installing. Press on to the stop when installing so that there is no axial clearance.
• Do not interchange the outer or inner races of bearings of the same size.
• Tapered roller bearings installed on a shaft must be replaced as a set and use same make of bearings.
• Install needle bearings with lettered side (thicker metal) towards fitting tool.

Adjusting Shims 

• Use a micrometer to measure the shims at several points. Tolerance variations make it possible to find the exact shim thickness required.
  Fig 4: Identifying Micrometer Caliper To Measure Adjusting Shims

  Courtesy of AUDI OF AMERICA, LLC
• Check for burrs and damage.
• Only install perfect shims.

Synchronizer Rings 

• When reusing synchronizer rings, do not interchange them and always assign them to the same selector gear.
• Check for wear and replace if necessary.
• Check the grooves -arrow 1- of synchronizer ring -A- and inner race for flat areas (grooves are worn).
  Fig 5: Checking Synchronizer Rings For Wear

  Courtesy of AUDI OF AMERICA, LLC
• For coated synchronizer rings, coating must not be damaged.
• If an intermediate ring -B- is installed, check the intermediate ring on the outer contact surface -arrow 2- and inner contact surface -arrow 3- for grooves, scoring and blue coloring (from overheating).
• Check taper of drive gear for grooves and scoring.
• Coat with gear oil before installing.

Gears 

• Clean prior to pressing on.
• For installation heat to approximately 100 °C (212 °F) with the inductive heat unit VAS 6414 and during installation press on to the stop so that there is no axial clearance.

Selector Gears and Sliding Sleeves 

• After installing, check 1st through 6th gear for minimal amount of axial clearance and for ease of movement.

• Damage to the synchronizer ring or gear wheel:
  Fig 6: Identifying Damage To Synchronizer Ring Or Gear Wheel

  Courtesy of AUDI OF AMERICA, LLC

A - Worn clutch spline camber on the synchronizer ring or gear wheel

• Compare: synchronizer ring or gear wheel not damaged:
  Fig 7: Identifying Comparison Of Undamaged Synchronizer Ring Or Gear Wheel

  Courtesy of AUDI OF AMERICA, LLC

B - Worn clutch spline camber on the synchronizer ring or gear wheel

• Picture of damage on the locking collar:
  Fig 8: Identifying Damage On Locking Collar

  Courtesy of AUDI OF AMERICA, LLC

C - Worn longitudinal inner spline camber and the locking collar

• Comparison: locking collar not damaged:
  Fig 9: Identifying Locking Collar Undamaged

  Courtesy of AUDI OF AMERICA, LLC

D - Undamaged longitudinal inner spline camber and the locking collar

Clutch Mechanism, Clutch 

• If the clutch pedal does not return to the starting position (rest position) after the recoupling procedure, bleed the clutch system (further measures. Refer to INFORMATION REGARDING THE REMOVAL AND INSTALLATION OF THE CLUTCH MASTER OR SLAVE CYLINDER ).
• Do not tilt clutch pressure plate; loosen and tighten one after another in 90° increments.
• To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.
• Only use compressed air to blow out the dual-mass flywheel.
• The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the pressure plate. This will shorten the service life of the clutch considerably.
• The friction surfaces on the pressure plate and on the dual mass flywheel must be cleaned thoroughly (degreased).