Section 40 (5 SPD. Manual Transmission 02J (A4 Platform))
WARNING: This page is about a different variant/trim than selected.
- 00 General, Technical Data
- 30 Clutch
- Clutch control, servicing
- Clutch release mechanism, servicing
- Clutch, servicing
- 34 Manual Transmission - Controls, Housing
- Gear selector mechanism up to 05.99, servicing
- Gear selector mechanism from 05.99, servicing
- Transmission, removing and installing
- Gear oil, checking
- Transmission, disassembling and assembling
- Overview
- Assembly overview
- Cover for transmission housing and 5th gear, removing and installing
- Transmission housing and selector mechanism, removing and installing
- Input shaft, output shaft (pinion shaft), differential and selector forks, removing and installing
- Assembly sequence
- Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks
- Notes
- Disassembling
- Assembling
- Installation position 5th gear
- Checking 5th gear synchro-ring
- Installation position 5th gear synchro-hub/locking collar
- 5th gear synchro-ring with cast locking pieces (arrows)
- Installation position of dished spring for gear and 5th gear synchro-hub securing bolts
- Adjusting 5th gear
- Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks
- Transmission housing and clutch housing, servicing
- Transmission selector mechanism up to 05.99, disassembling and assembling
- Transmission selector mechanism from 05.99, disassembling and assembling
- Selector forks, disassembling and assembling
- 35 Manual Transmission - Gears, Shafts
- Input shaft, disassembling and assembling
- Notes
- Pressing out tapered roller bearing outer race
- Pressing in tapered roller bearing outer race
- Pressing on tapered roller bearing inner race
- Pressing off 4th gear with tapered roller bearing and sleeve
- Pressing off 3rd gear
- Pressing on 3rd gear
- Pressing on 4th gear
- Pressing on sleeve for needle roller bearing
- 5th gear synchronizer
- Assembling 5th gear locking collar/synchro-hub
- Input shaft, adjusting
- Output shaft, disassembling and assembling
- Output shaft, disassembling and assembling
- Notes
- Pulling out small tapered roller bearing outer race
- Pressing in small tapered roller bearing outer race
- Pulling off small tapered roller bearing inner race
- Pressing on small tapered roller bearing inner race
- Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gears with transmission housing needle roller bearing sleeve
- Pulling off locking collar with synchro-hub via bearing support
- Pulling off large tapered roller bearing inner race
- Pressing on large tapered roller bearing inner race
- Checking synchro-ring for wear
- Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
- Assembling 1st and 2nd gear locking collar/synchro-hub
- Installation position 1st and 2nd gear locking collar/synchro-hub
- Pressing on 1st and 2nd gear locking collar/synchro-hub
- Identifying 1st and 2nd gear synchro-rings
- Distinguishing 1st and 2nd gear synchro-rings
- Checking 2nd gear synchro-ring for wear
- Installation position outer-ring
- Checking inner ring for wear
- Installation position synchro-ring (inner-ring) -A-
- Installation position 2nd gear
- Pressing on needle roller bearing sleeve for 3rd gear
- Disassembling and assembling 3rd and 4th gear locking collar and synchro-hub
- Assembling 3rd and 4th gear locking collar/synchro-hub
- Installation position 3rd and 4th gear locking collar/synchro-hub
- Pressing on 3rd and 4th gear synchro-hub with locking collar
- Pressing on sleeve for 4th gear needle roller bearing
- Pressing on sleeve for output shaft needle roller bearing
- Modified 1st gear synchronization from transmission build date 02 05 0
- Notes
- Installation position of inner ring, outer ring and synchro-ring 1st gear:
- Check inner ring 1st gear for wear
- Check synchro-ring 1st gear and outer ring for wear
- Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub
- Installation position of locking collar/synchro-hub 1st and 2nd gear
- Output shaft, disassembling and assembling
- Output shaft, adjusting
- Reverse shaft, disassembling and assembling
- Input shaft, disassembling and assembling
- 39 Final Drive, Differential
- Flange shaft oil seals, replacing
- Differential, disassembling and assembling
- Differential, disassembling and assembling
- Notes
- Driving tapered roller bearing outer race out of clutch housing
- Pressing tapered roller bearing outer race into clutch housing
- Pulling off tapered roller bearing inner race
- Pressing on tapered roller bearing inner race
- Pulling tapered roller bearing outer race out of transmission housing
- Pressing tapered roller bearing outer race into transmission housing
- Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs
- Drilling out rivet heads
- Pressing off final drive gear
- Installation position of final drive gear
- Heating final drive gear to approx. 100 ° C and installing
- Bolting final drive gear and differential housing together
- Removing and installing differential pinion shaft spring pin
- Installing differential side gears and pinion gears
- Differential, disassembling and assembling
- Adjustment overview
- Differential