Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also 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 Repair Manual, are summarized here. They apply to this repair manual.

Special Tools and Equipment

Complete list of special tools used in this Repair Manual.

Transmission 

• Servicing, refer to Removal and Installation .
• Allocate bolts and other components according to transmission code using the electronic parts information. Refer to Audi A4 or Audi A5 ENGINE CODES, TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES .
• Check the transmission fluid level when replacing the manual transmission and fill if necessary. Refer to MANUAL TRANSMISSION, CHECKING TRANSMISSION FLUID LEVEL .
• Capacities and specifications, refer to Audi A4 or Audi A5 ENGINE CODES, TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES .
• Always clean the connection locations and the area around them before loosening.
• When installing transmission, make sure that the alignment bushings are installed correctly.

Sealant 

• Always thoroughly clean the separating surfaces on the housing before applying the sealant.
• Apply sealing paste 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 Sealing 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 seals, 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 Seals Sealing Lips

  Courtesy of AUDI OF AMERICA, LLC
• The open side of the shaft seal points toward the fluid to be sealed in.
• 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 MANUAL TRANSMISSION, CHECKING TRANSMISSION FLUID LEVEL .

Fasteners 

• 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: Slit -A- should in line with the line of force -arrow-.
  Fig 2: Identifying Locking Elements

  Courtesy of AUDI OF AMERICA, LLC

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 compound AMV 185 101 A1.
• 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.

Adjusting Shims 

• Measure the adjusting shims at several locations with a mircometer. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Only install perfect, undamaged shims.

Bearings 

• Install needle bearings with lettered side (thicker metal) facing the fitting tool.
• Grease the needle bearing for transmission output 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 SLAVE CYLINDER INFORMATION ).
• 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.