Renewing gearbox cover (with gearbox installed) — AUDI

Audi
Audi A4
2001
Audi A4 Cabriolet
2003
Power transmission
5-speed manual gearbox 012, 01W, 0A9, front-wheel drive
Edition
03.2015
Renewing gearbox cover (with gearbox installed)
Special tools and workshop equipment required
Drip tray
V.A.G 1306
or
drip tray for workshop hoist
VAS 6208
Engine and gearbox jack
V.A.G 1383 A
Universal dial gauge bracket
VW 387
Thrust plate
VW 401
Press tool
VW 407
Tube
VW 420
Multi-purpose tool
VW 771
Assembly device
VW 792
Thrust plate
3005
Multi-point bit
3357
1
Internal puller
Kukko 21/1
Dial gauge
Dial gauge extension
Depth gauge
(accurate to within
5
/
100
mm or less)
Sealant
AMV 188 001 02
Removing gearbox cover
WARNING
Follow steps required when disconnecting battery
Rep. gr.
27
.
On vehicles with telematics: activate service mode of telematics control unit before disconnecting battery
Rep. gr.
91
.
Refer to coding on vehicles with encoded radio/radio navigation system (RNS); obtain coding if necessary.
With the ignition switched off, disconnect battery earth strap.
Note
The gearbox cover can be renewed with the gearbox installed.
If fitted, loosen quick-release fasteners
2
and
3
and remove rear noise insulation
B
.
Place
drip tray
V.A.G 1306
or
drip tray for workshop hoist
VAS 6208
under vehicle.
Use
multi-point bit
3357
to remove oil drain plug
arrow
and allow gear oil to drain off completely.
Screw oil drain plug back in and tighten to 25 Nm.
If fitted, remove bolts
arrows
and detach covers
1
and
2
.
Remove tunnel cross piece (front)
1
arrows
.
Vehicles with 4-cylinder engine:
Remove front exhaust pipe
3
in front of clamp
2
Rep. gr.
26
.
Vehicles with 6-cylinder engine:
Separate exhaust system at clamps
arrows
and remove front exhaust pipe (right-side) with catalytic converter
Rep. gr.
26
.
Vehicles with 6-cylinder 3.0 ltr. engine:
Remove Lambda probe in front of catalytic converter (left-side) at bottom
Rep. gr.
26
.
All vehicles:
Remove heat shield
4
above exhaust system/catalytic converters.
Apply lifting column of
engine and gearbox jack
V.A.G 1383 A
to gearbox from below (with
gearbox support
T10337
attached).
First remove bolts
3
and then bolts
2
at tunnel cross member
A
.
Lower gearbox slightly.
Remove both nuts
1
from gearbox mounting
B
and detach tunnel cross member
A
.
Lower
engine and gearbox jack
V.A.G 1383 A
and move it aside.
Remove selector rod
arrow A
.
Unscrew hexagon socket head bolt on push rod
arrow B
.
If fitted, pull connector out of bracket
arrow
.
Unplug connector
1
and move wiring
2
clear.
Remove retainer for wiring
3
.
Unbolt gearbox support with gearbox mounting
arrows
.
Place
drip tray
V.A.G 1306
or
drip tray for workshop hoist
VAS 6208
under vehicle.
Unscrew bolts
1
and
2
and remove gearbox cover.
Note
Only bolts
2
used on gearboxes with magnesium housing are fitted with a washer.
If fitted, pull out securing bush for outer race for small tapered roller bearing.
A
Internal puller 12...14.5 mm
, e.g.
Kukko 21/1
Note
The securing bush does not have to be reinstalled.
Screw
adapter
VW 771/40
into pressure plate.
Attach
multi-purpose tool
VW 771
and pull outer race out via the pressure plate.
Remove circlip
1
and support plate
2
.
Remove reverse gear wheel
3
and needle bearing and thrust washer located behind.
Screw self-tapping screw
arrow
into centre of rubber disc
4
and pull out disc by means of self-tapping screw.
Installing gearbox cover
Make sure the following components are fitted in the new gearbox cover:
Reverse gear shaft
Roller bearing
Oil collector
Bearing bush for ball sleeve
Install reverse gear wheel with thrust washer, needle bearing, support plate and circlip
Chapter
.
Also check that both plugs
arrows
are pressed into gearbox cover.
Re-determining thickness of shim
“S
4
”
:
Thoroughly clean sealing surface of housing and bearing seat on old and new gearbox covers.
Note
Position of shim
“S
4
”
Chapter
.
Use
depth gauge
(accurate to within
5
/
100
mm or less)
Measure difference in depth
“a”
on old and new gearbox cover.
Example:
Depth
“a”
(old gearbox cover)
257.40 mm
Depth
“a”
(new gearbox cover)
257.56 mm
=
Difference
0.16 mm
If new gearbox cover is deeper, install a thicker
“S
4
”
shim.
If previous gearbox cover is deeper, install a thinner
“S
4
”
shim.
Example:
Previous shim
“S
4
”
0.69 mm
+
Difference
0.16 mm
=
New shim
“S
4
”
0.85 mm
Shims available
.
Clean rubber disc
4
and pressure plate
3
and insert in gearbox cover.
Install newly determined shim
“S
4
”
2
and outer race for tapered roller bearing
1
.
Press outer race for tapered roller bearing into gearbox cover.
Thoroughly clean sealing surface on gearbox housing.
Note
Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.
Fit gearbox cover and tighten bolts to 22 Nm.
Checking preload of tapered roller bearings for pinion shaft
Note
Make sure that no gear is engaged when performing the next work step.
Give both front wheels 1
1
/
2
turns in each direction so that tapered roller bearing settles.
Set up measuring tools and secure with bolt
arrow
to gearbox housing.
Apply dial gauge (3 mm measuring range) onto centre of gearbox cover and set to
“0”
with 2 mm preload.
Loosen all gearbox cover bolts approx. one turn.
If the correct shims have been selected the dial gauge will now indicate the following value:
0.05…0.15 mm
Detach measuring tools and gearbox cover.
Clean sealing surface thoroughly for a second time and apply a thin coat of
sealant
AMV 188 001 02
.
Note
Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.
Fit gearbox cover and tighten bolts
1
and
2
to 22 Nm.
Note
Only bolts
2
used on gearboxes with magnesium housing are fitted with a washer.
Fit oil seal as follows:
Pack space between sealing lip and dust lip half-full with
sealing grease
G 052 128 A1
.
Lightly oil outer circumference of oil seal.
Use
tube
VW 420
to insert oil seal.
Dimension
a
= 1 mm
Secure gearbox mounting
arrows
.
If fitted, attach retainer for wiring
3
and engage connector
1
and wiring
2
.
Push selector rod on so that the securing bolt fits in the recess in the selector shaft.
Then secure selector rod
arrow A
.
Then bolt push rod to gearbox
arrow B
.
Secure tunnel cross member
A
to gearbox mounting
B
with nuts
1
.
Use
engine and gearbox jack
V.A.G 1383 A
to lift gearbox far enough to be able to screw in the bolts
2
.
First tighten bolts
2
and then bolts
3
to specified torque.
Lower
engine and gearbox jack
V.A.G 1383 A
and move it aside.
Install heat shield
4
above exhaust system/catalytic converters.
Install front exhaust pipe
3
and/or catalytic converter
Rep. gr.
26
.
Align exhaust system so it is free of stress
Rep. gr.
26
.
Install tunnel cross piece (front)
1
.
Check selector mechanism setting and adjust if necessary
Chapter
.
Fill up oil in gearbox and check oil level
Chapter
.
Install rear noise insulation (if fitted).
Connect the battery.
Note
When reconnecting battery, remember to activate vehicle equipment (radio/navigation system, clock, electric window) according to Owner's Manual.
Deactivate telematics control unit service mode
Rep. gr.
91
.
Tightening torques
Gearbox support with gearbox mounting to gearbox
Bolts
arrows
23 Nm
Tunnel cross member to gearbox mounting and body
Component
Nm
1
Tunnel cross member to gearbox mounting
23
2
Tunnel cross member to body
1)
110 Nm + 90°
2)
3
Tunnel cross member to body
1)
M10
55
1)
Always renew bolt with washer
2)
90° is equivalent to a quarter turn
Component
Nm
Oil drain plug
25
Gearbox cover to gearbox housing
22
Selector rod/selector joint to gearbox
1)
23
Push rod to gearbox
40
Tunnel cross piece (front) to body
55
Clamp for exhaust pipe
40
1)
Renew bolt