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General Repair Information






General Repair Information

To ensure perfect and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. The usual basic safety precautions also apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the Repair Information, are summarized here. It applies to this repair information.

Transmission

• Transmission, disassembling and assembling. Refer to =>
Overhaul

• Allocate bolts and other components according to transmission code. [ Audi A4 Engine Codes, Transmission Allocation, Ratios, Capacities, from MY 2001 ] Audi A4 Engine Codes, Transmission Allocation, Ratios, Capacities, From MY 2001 or => [ Audi A4 Cabriolet Engine Codes, Transmission Allocation, Ratios, Capacities, from MY 2003 ] .

• When changing a transmission, check oil level and add oil if necessary. Refer to => [ Manual Transmission, Checking Gear Oil Level ] 0A3A Transmission.

• Capacities and specifications. Refer to => [ Audi A4 Engine Codes, Transmission Allocation, Ratios, Capacities, from MY 2001 ] Audi A4 Engine Codes, Transmission Allocation, Ratios, Capacities, From MY 2001 or => [ Audi A4 Cabriolet Engine Codes, Transmission Allocation, Ratios, Capacities, from MY 2003 ] .

• Thoroughly clean all connections and the surrounding area before disconnecting.

• When installing transmission, make sure that the alignment bushings are fitted correctly.

Sealant

• Thoroughly clean housing joint surfaces before applying sealing compounds.

• Apply Sealing Paste (AMV 188 001 02 ) evenly and not too thick.

• Do not allow sealing compound to enter ventilation openings.

O-rings, gaskets, seals

• O-rings, gaskets and seals must be replaced.

• 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.

• Thoroughly clean housing joint surfaces before assembling.

• Before installing radial shaft seals, lightly oil outer circumference and fill space between sealing lips - arrow - halfway with Sealing Grease (G 052 128 A1).





• The open side of the gaskets points toward the fluid to be sealed in.

• When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

• After replacing seals and gaskets, check and, if necessary, top off oil level in final drive. Refer to => [ Manual Transmission, Checking Gear Oil Level ] 0A3A Transmission.

Fasteners

• Do not over-stretch circlips.

• Always replace damaged or over-stretched circlips.

• Circlips must locate properly in the groove.

• Replace spring pins. Installation position: Slit - A - should be in line with the line of force- arrow -.





Bolts and Nuts

• Loosen bolts and nuts in reverse of tightening sequence.

• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.

• Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.

• The tightening specifications stated apply to non-oiled nuts and bolts.

• Replace self-locking bolts and nuts.

• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with Locking Fluid (AMV 185 101 A1 ).

• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Adjusting Shims

• Use a micrometer to measure the shims at several points. Tolerance variations make it possible to find the exact shim thickness required.

• Check for burrs and damage.

• Do not install shims which are damaged or not in perfect condition.

Mount

• Install needle bearings with lettered side (thicker metal) towards fitting tool.

• Grease rear transmission input shaft needle bearing in flywheel.

• Insert all bearings in transmission housing with transmission oil.

Hydraulic

• When removing transmission, remove clutch slave cylinder without disconnecting 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 thereby be 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 ] 0A3A Transmission).

• Observe assembly instructions for SAC pressure plate. Refer to => [ Clutch with SAC Pressure Plate ] Clutch With SAC Pressure Plate.

• On vehicles with SAC pressure plate, an adjusting ring must be reset if only the clutch plate is being replaced. Refer to => [ SAC Clutch Pressure Plate Adjusting Ring, Resetting ] 0A3A Transmission.

• To reduce odor caused by a burnt clutch, thoroughly clean the clutch bell housing, the flywheel and the side of the engine facing toward the transmission.
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