Repair instructions

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. 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 article, are summarized here. They apply to this article.

Transmission

When replacing rear final drive the oil level in rear final drive must be checked and, if necessary, corrected. Refer to Gear oil level in rear final drive, checking .
Capacities and specifications. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD .
When assembling mounting brackets as well as waxed components clean contact surfaces. The contact surfaces must be free of wax and grease.

Gaskets, sealing rings

Replace O-rings.
Radial shaft oil seals.

Before installing:

Fig 1: Identifying Space Between Oil Seal Sealing Lips

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052 128 A1.

After installation:

Check gear oil in rear final drive; if necessary top off to lower edge of oil filler hole, specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD .

Locking elements

Replace circlips.
Do not over-stretch circlips.
Circlips must be properly seated in the base of the groove.

Fig 2: Identifying Spring Pins Installation Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace spring pins.

Installation position: Slot longitudinal to line of force.

Nuts, bolts

Nuts and bolts which secure covers and housings should be loosened and tightened diagonally.
Parts which are particularly sensitive must not be tilted; loosen or tighten diagonally in stages.
Tightening torques stated apply to non-oiled nuts and bolts.
Replace self-locking bolts and nuts.

Make sure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after assembly, if necessary.

Bearings

Attach needle bearing with the written side (greater plate thickness) to the installing tool.
Install new taper roller bearings in delivery condition and do not oil.
Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Heat inner races to approx. 100°C before installing.

Do not interchange outer or inner races of bearings of the same size. The bearings are paired.

Adjustment shims

Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it possible to obtain exact shim thickness required.
Check for burrs and damage.
Install only adjustment shims which are in perfect condition.