General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. 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 Workshop Manual, are summarized here. They apply to this service information.

Special Tools and Equipment

Transmission

• Servicing. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .
• Allocate the bolts and other components according to transmission code . Refer to TRANSMISSION/ENGINE ALLOCATION .
• Check the transmission fluid level when replacing the manual transmission and fill if necessary. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
• Capacities and specifications. Refer to CAPACITIES .
• Always clean the connection locations and the area around them before loosening.
• When installing transmission, make sure that the alignment bushings are fitted correctly.

Sealant

• Always thoroughly clean the separating surfaces on the housing before applying the sealant.
• Apply the Sealant AMV 188 001 02 evenly and not too thick.
• Do not allow any Sealing Compound to get into the ventilation holes.

O-rings, Seals, Shaft Seals and Gaskets

• O-rings, gaskets and seals must be replaced.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• Clean the housing separating surface thoroughly before assembling.
• Before installing the shaft seal lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with Grease G 052 128 A1.
  Fig 1: Identifying Oil Seal Sealing Lips

  Courtesy of AUDI OF AMERICA, LLC
• The open side on the shaft seals faces the fluid to be sealed off.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
• After replacing the seals and sealing rings, check the transmission fluid level and fill if necessary. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

Fasteners

Fig 2: Identifying Circlips

Courtesy of AUDI OF AMERICA, LLC

• Do not overstretch the circlips.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: the slit -A- should align with the line of force -arrow-.

Bolts and Nuts

• Loosen the bolts and nuts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.
• Parts which are particularly sensitive to distortion must be kept straight when removing and installing; loosen or tighten diagonally in stages.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Always replace self-locking nuts and bolts.
• Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Install the bolts with Locking Fluid AMV 185 101 A1.
• If self-locking bolts were installed or if regular bolts were installed with locking fluid, then the threaded holes must be cleaned, for example with a thread tap. If the holes are not cleaned, then the bolts could break off the next time they are removed.

Adjusting Shims

• Measure the adjusting shims at several locations with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Only install perfect shims that have never been damaged.

Bearings

• Install needle bearings with lettered side (thicker metal) racing the fitting tool.
• Grease the needle bearing for the transmission input shaft in the drive plate.
• Insert all bearings in transmission housing with transmission oil.

Clutch Mechanism

• When removing transmission, remove the clutch slave cylinder without opening the lines.
• If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the clutch slave cylinder. The clutch slave cylinder will get damaged.
• If the clutch pedal does not return to the starting position (rest position) after recoupling it, bleed the clutch system (further measures. Refer to CLUTCH MASTER OR CLUTCH SLAVE CYLINDER, REMOVAL AND INSTALLATION INFORMATION and CLUTCH MECHANISM, BLEEDING ).
• 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 clean the clutch module.
• Change the fluid for the clutch system at the same interval when changing the brake fluid for the brake system. Refer to CLUTCH MECHANISM, BLEEDING . Procedure Descriptions; Changing Brake Fluid (every 2 years).