Overhaul - 01v Audi A4 B5

IDENTIFICATION

TRANSMISSION IDENTIFICATION

TRANSMISSION

The 5-speed automatic transmission 01V is installed in conjunction with the 4 and 6-cylinder engines. See CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT .

Transmission code letters are located on the data plate under the transmission (arrow). (Scheme 114)

Scheme 114

There is another identical data plate on side of transmission which is not accessible with the transmission installed.

Transmission code number and transmission serial number.

Transmission serial number (arrow 1), Transmission identification (arrow 2), Code letter (arrow 3). (Scheme 115)

Scheme 115

The transmission code letters are also listed on the vehicle data plates.

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

TORQUE CONVERTER

The torque converter is equipped with a lock-up clutch. The lock-up clutch is closed load- and speed-dependant with minimum pulsations and mechanically drives the 3., 4. and 5. gear independent of slip.

5-speed automatic transmission 01V is equipped with 5 hydraulically activated forward gears. By passing the torque converter slip, these forward gears become mechanically driven gears if the lock-up clutch is closed.

HYDRAULIC CONTROL

There is a distinction made between two types of transmission. Transmissions with hydraulic control E17, the sensor for transmission RPM (inductive sensor) is secured to bottom of valve body. Transmissions with hydraulic control E18/2, the sensor for transmission RPM (hall effect sensor) is secured to transmission housing behind valve body.

Information regarding which transmission is installed can be found in tables CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT onward.

ON BOARD DIAGNOSTIC (OBD)

On Board Diagnostic (OBD) is described in: appropriate DIAGNOSIS 01V article.

ROLL STARTING AND TOWING, NOTES

Roll starting the engine is not possible (e.g. if the battery is too weak or the starter does not work).

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L article.

AXLE SHAFTS

For information on axle shaft, see AXLE SHAFTS - FRONT & REAR article.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L) article.

REPAIR INSTRUCTIONS

The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.

1. Rules of cleanliness for working on automatic transmissions. See «RULES OF CLEANLINESS FOR WORKING ON AUTOMATIC TRANSMISSIONS»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__rules-of-cleanliness-for-working-on) .
2. Do not run engine with the oil pan removed or without ATF filling and do not tow vehicle.
3. Secure torque converter on removed transmission to keep it from falling out.
4. Thoroughly clean all connections and the surrounding area before disconnecting.
5. Check installation dimension of torque converter before installing transmission. See «TORQUE CONVERTER, INSTALLING»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v) .
6. When installing transmission, make sure centering sleeves are correctly seated.
7. Place parts that have been removed on a clean surface and cover. Use foils and paper. Use lint-free cloths only!
8. Carefully cover over opened components or seal, if repairs are not carried out immediately.
9. Only install clean components: Only unpack replacement parts immediately prior to installation.
10. Check, and if necessary correct amount of the following fluids when replacing the automatic transmission. ATF in planetary gear, Gear oil in front final drive, Transmission oil in center differential and Capacities and specifications. See «SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L»(/audi/a4/b5-1994-1999/remont/automatic-trans/#servicing-at-01v-with-18l-27l-28l) article.
11. When replacing the rear final drive, check and if necessary, correct oil level in rear final drive Capacities and specifications. See «SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L»(/audi/a4/b5-1994-1999/remont/automatic-trans/#servicing-at-01v-with-18l-27l-28l) article.

O-RINGS, GASKETS, SEALS

1. Always replace O-rings, gaskets and sealing rings.
2. 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.
3. Thoroughly clean housing joint surfaces before assembling and apply sealing compound AMV 188 200 03.
4. Before installing, fill gap between sealing lips of radial-shaft seals half way with sealing grease 052 128 A1.
5. The open side of the seals face toward the fluid to be sealed in.
6. For installation, lightly coat outer circumference and sealing lip with ATF or transmission oil, depending on the installation location.
7. Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
8. Use only ATF in areas near ATF. Other lubricating substances cause functional problems in the hydraulic transmission control.
9. When pressing in new seals, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
10. After installing, check and if necessary correct fluid levels in the affected area. ATF in planetary gear, Gear oil in front final drive, Transmission oil in center differential, Transmission oil in rear final drive, and Capacities and specifications. See «SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L»(/audi/a4/b5-1994-1999/remont/automatic-trans/#servicing-at-01v-with-18l-27l-28l) article.

NUTS, BOLTS

1. Loosen bolts in reverse order of tightening sequence.
2. Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
3. Do not cant, and loosen and tighten especially sensitive parts (e.g. valve body) in diagonal manner in stages.
4. The tightening torques stated apply to non-oiled nuts and bolts.
5. Always replace self-locking nuts and bolts.
6. Using a wire brush, clean threads of bolts which are secured with locking compound. Next, insert bolts using AMV 185 101 A1.
7. Threaded holes into which self-locking bolts or bolts with locking compound are threaded in, must be cleaned (e.g. using threaded tap). Otherwise there is danger that the bolts may shear when removed again.

CIRCLIPS

1. Do not over-stretch circlips.
2. Always replace damaged or over-stretched circlips.
3. Circlips must be fully seated in grooves.
4. Replace roll pins. Installation position: Slot is longitudinal to line of force. (Scheme 132)

Scheme 131

MOUNTS

1. Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the drift.
2. Insert bearing with transmission oil or ATF, depending on installation location.
3. Tapered roller bearings for output shaft and differential in rear final drive are low-friction bearings. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory for this reason.
4. Do not interchange inner and outer bearing races with those from other bearings of the same size.
5. Tapered roller bearings are allocated to the date of transmission manufacture and code letters.
6. Always replace tapered roller bearings on one shaft together and use new bearings from the same manufacturer.
7. Heat tapered roller bearing inner races to approx. 100° C before installing. Press in to stop so that there is no axial play.

SHIMS

1. Measure shims at several points using a micrometer. Different tolerances make it possible to measure the required shim size exactly.
2. Check for burrs and signs of damage. Only install perfect adjustment shims.
3. Only install perfect undamaged adjustment shims.

VALVE BODY

1. Replace valve body if shift members are burnt.
2. The valve body is allocated to the transmission code letters. See «CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v) .

GUIDED TROUBLESHOOTING, VEHICLE ON BOARD DIAGNOSTIC (OBD) & TEST INSTRUMENTS

1. Before performing repairs on the automatic transmission, the malfunction cause must be determined as precisely as possible via the VAS 5051 Tester in operating modes "Guided Troubleshooting", "Vehicle Self-Diagnosis" and "Test Instruments."

On Board Diagnostic (OBD) is described in DIAGNOSIS - 01V article.

Scheme 132

1. Rules of cleanliness for working on automatic transmissions. See «RULES OF CLEANLINESS FOR WORKING ON AUTOMATIC TRANSMISSIONS»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__rules-of-cleanliness-for-working-on) .
2. General repair notes. See «REPAIR INSTRUCTIONS»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__repair-instructions) .
3. Lightly coat sealing ring with ATF. Other lubricating substances lead to functional problems in the hydraulic transmission control.

TORQUE CONVERTER, IDENTIFICATION

Different types of torque converters exist. Identification is performed via code letters (arrow). (Scheme 134)

Scheme 133

Allocation of torque converter/transmission see CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT .

TORQUE CONVERTER, CHECKING

Checking converter hub for wear grooves (arrow). (Scheme 135)

Scheme 134

Note. The torque converter is welded in and must be completely replaced if damaged or in case of malfunctions.

Scheme 135

1. VAG1358A - oil siphoning unit
2. V.A.G 1358 A/1 oil siphoning probe (Scheme 136)

In case of soiling of the ATF via shavings or during a major transmission overhaul, torque converter must be drained.

Draining Torque Converter

Drain ATF from torque converter using VAG1358A and oil siphoning probe VAG1358A/1. (Scheme 137)

Scheme 136

Scheme 137

1. VW681 extractor lever
2. 3295 thrust piece (Scheme 138)

Removing

Removing transmission. See REMOVAL & INSTALLATION - A/T (01V - WITH 2.7L) or REMOVAL & INSTALLATION - A/T (01V - WITH 1.8L & 2.8L) article.

Secure transmission to transmission mount or place on flat surface.

Insert VW681 extractor lever directly behind the sealing lip of the sealing ring, so that the contact ring which is behind it is not damaged. (Scheme 139)

Scheme 138

Installing

Insert contact ring.

Coat outer circumference and sealing lips of sealing ring with ATF.

1. Installation position: The open side of the sealing ring faces the transmission.

Using 3295 thrust piece, drive in sealing ring for torque converter up to thrust piece stop. (Scheme 140)

Scheme 139

Special Tools & Equipment

1. Depth gauge

Slide in converter hub through the sealing ring up to the first stop.

Rotate torque converter inward with light pressure, until the groove of the torque converter hub engages in the coupling plate of the pump wheel and the torque converter slides inward noticeably.

Installation Dimension

If the torque converter is inserted properly, the dimension between the surface of the mounting eyes and the surface of the torque converter housing is at least 23 mm. (Scheme 141)

Scheme 140

If the torque converter is not inserted completely, this distance will be approx. 11 mm.

Scheme 141

Scheme 142

Scheme 143

Remove oil pan and oil ATF screen. See TRANSAXLE OIL PAN & ATF SCREEN in SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L) article. Disconnect clip for wiring harness connectors (arrows). (Scheme 144)

Note. To determine which valve body type is installed in transmission, see code tables in FRONT WHEEL DRIVE (FWD) or ALL WHEEL DRIVE (AWD) .

On vehicles equipped with E17 valve body, pull connector (arrow or "A") off transaxle vehicle speed sensor. (Scheme 145) On vehicles equipped with E18 valve body, pull connector (A) off transaxle vehicle speed sensor. (Scheme 146) Pull connector (B) off transaxle RPM sensor.

Scheme 144

Scheme 145

On both valve bodies, ONLY remove bolts from valve body which are marked with an arrow. (Scheme 147) On E18 valve body, bolt (A) does not apply and should be ignored. On E17 valve body, bolt (A) is shorter than all other bolts.

Scheme 146

On E17 valve body, DO NOT place valve body upside down on transaxle RPM sensor. There is a risk of damage.

On both valve bodies, do not remove any other bolts as this could influence function of valve body. Detach valve body from transaxle and guide out connector on wiring harness.

To install, reverse removal procedure. On E18 valve body, to ensure wiring harness does not become trapped when installing valve body, route wire with connector (C) according to illustration. (Scheme 148)

Scheme 147

Note. For installation position, ensure flat portion of rear collar points downward, tabs at collar are horizontal.

On both valve bodies, lubricate NEW "O" rings for connector on wiring harness with ATF. Insert wiring harness connector into transmission housing. Place valve body in position so that pin of detent plate (1) engages in slot on selector slide (2). (Scheme 149)

Scheme 148

Tighten bolts (arrows) hand tight, securing valve body. On E18 valve body, bolt (A) does not apply and should be ignored. On E17 valve body, bolt (A) is shorter than all other bolts. (Scheme 147)

Tighten valve body bolts to specification, working from inside of valve body outward, to 71 INCH lbs. (8 N.m).

Connect transaxle vehicle speed sensor connector. Pull up wire to transaxle RPM sensor (if equipped) between valve body and wiring harness.

On E18 valve body, pull wiring with connector (B) of sensor for transmission RPM (G182) between valve body and wiring harness upward and reconnect harness connector. (Scheme 146) Connect harness connector (C) to transmission vehicle speed sensor (G38). On E17 valve body, connect harness connector (arrow) to transmission vehicle speed sensor (G38). (Scheme 145)

On all valve bodies, connect clip to wiring harness connector (arrow). (Scheme 144) Install ATF screen and oil pan. See SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L article.

Fill transaxle with ATF, check ATF level and top off. See SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L article.

TRANSMISSION, DISASSEMBLING & ASSEMBLING

Observe general repair instructions. See REPAIR INSTRUCTIONS .

RULES OF CLEANLINESS FOR WORKING ON AUTOMATIC TRANSMISSIONS

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover. Use foils and paper. Use lint-free cloths only!
3. Carefully cover over opened components or seal, if repairs are not carried out immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation.
5. Always replace O-rings, gaskets and sealing rings.
6. Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
7. Use only ATF in areas near ATF. Other lubricating substances cause functional problems in the hydraulic transmission control.
8. Check the following fluid levels after installing, top off if necessary. ATF in planetary gear , Gear oil in front final drive, Transmission oil in center differential. Capacities and specifications, see «SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L»(/audi/a4/b5-1994-1999/remont/automatic-trans/#servicing-at-01v-with-18l-27l-28l) article.

Scheme 149

1. Rear final drive removed.

1. VAG1306 drip tray.

Secure complete rear final drive to assembly stand.

Place VAG1306 drip tray underneath and drain gear oil.

Remove left and right drive flanges.

To loosen securing bolt, thread 2 bolts into drive flange and counter hold using tire iron. (Scheme 151)

Scheme 150

Mark left and right drive flanges.

Remove drive flange at installed bolts.

Remove mounting bolts for final drive cover.

Remove final drive cover from axle housing and remove differential.

Installation is reverse of removal, noting the following

Install differential.

Replace O-ring for final drive cover and oil for installation.

Install final drive cover onto final drive housing and tighten in diagonal pattern to 25 Nm.

Replace drive flange seals. See SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L article.

Fill gap between sealing lip and dust lip with multi-purpose grease.

Install drive flanges and tighten to 25 Nm. (Scheme 151)

Top-up and check gear oil in rear final drive. See SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L article.

Scheme 151

Scheme 152

Scheme 153

1. VW295 needle bearing drift
2. VW401 thrust plate
3. VW402 thrust plate
4. VW407 punch
5. VW408A punch
6. VW412 punch
7. VW442 thrust pad
8. 40-21 sleeve
9. 40-105 thrust pad
10. 2050 thrust plate
11. 3138 drift
12. Tapered roller bearing puller VAG1582 taper roller bearing puller
13. VAG1582/6 attachment to VAG1582
14. Kukko 44/2 two-arm puller (Scheme 152)- (Scheme 154).

Scheme 154

Driving Small Tapered Roller Bearing Outer Race Out Of Housing

Check adjustment shims for damage after removing. (Scheme 156)

Scheme 155

Pressing Tapered Roller Bearing Outer Race Into Housing

Install outer race with VW295 needle bearing drift by tapping lightly using hammer.

Then drive in to stop, as shown in illustration. (Scheme 157)

Scheme 156

Scheme 157

Pressing On Small Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, position and press on. (Scheme 159)

Scheme 158

Pulling Off Large Tapered Roller Bearing Inner Race

Before installing removal tool, set 40-105 thrust piece onto differential housing. (Scheme 160)

Scheme 159

Pressing On Large Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, position and press on. (Scheme 161)

Scheme 160

Driving Large Tapered Roller Bearing Outer Race Out Of Cover

Check adjustment shims for damage after removing. (Scheme 162)

Scheme 161

Scheme 162

Scheme 163

Installing Ring Gear

When installing ring gear, guide with centering pins -A- (self-made). (Scheme 165)

Scheme 164

Heat ring gear to approx. 100° C and position.

Installing Small Differential Bevel Gears

If the large differential bevel gears were replaced, adjustment shims must be re-determined. See Adjusting Differential Bevel Gears .

Insert large differential bevel gears with determined adjustment shims.

Insert small differential bevel gears at 180° from their final position and rotate into place (arrow). (Scheme 166)

Scheme 165

Install thrust washers and locate.

Install threaded pieces.

Drive in differential bevel gear shaft to final position and secure.

Adjusting Differential Bevel Gears

Install large differential bevel gears with the thinnest shims (0.5 mm). (Scheme 167)

Scheme 166

Insert small differential bevel gears 180° from final position together with thrust washers.

Note. Do not rearrange differential bevel gears and thrust washers again!

Drive in shaft for differential bevel gears.

Press the small differential bevel gears toward the outside.

Push large differential bevel gears in direction of arrow and check play.

Determine the largest possible shim that can still be installed for the large differential bevel gears on each side.

1. Adjustment shims should be the same thickness on both sides.

Determine adjustment shims according to table. (Scheme 168)

Scheme 167

Note. The adjustment is also correct when no more play can be felt, but the differential bevel gears can just barely be rotated (arrow). (Scheme 169)

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

1. VW401 thrust plate
2. VW402 thrust plate
3. VW407 punch
4. VW408A punch
5. VW412 punch
6. VW457 support channels
7. VW460/2 drift
8. VW 519 sleeve
9. VW540 holding fixture
10. 30-205 thrust pad
11. 2003/3 seal installer
12. 2052/2 assembly tool for drive pinion
13. 3005 thrust pad
14. 3062 thrust pad
15. 3138 drift
16. 3253 wheel bearing assembly set with 3253/3 and 3253/4
17. 3304 retainer
18. Engine/transmission jack VAG1383A engine/gearbox jack (Scheme 170)- (Scheme 173).

1. Read general repair notes. See «REPAIR INSTRUCTIONS»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__repair-instructions) .
2. Disconnect torque tube from rear final drive with the final drive installed.
3. Disconnect torque tube from rear final drive with the final drive removed.
4. Replace both tapered roller bearings together. If possible, use same manufacturer!
5. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
6. Adjustments are required when replacing components marked with 1) see «Adjustment Overview»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__adjustment-overview) .

Scheme 173

Scheme 174

Removing Drive Pinion Nut

Install 3304 retainer using two hex bolts M8 x 30.

When nut is removed, final drive must be supported (e.g. using VAG1359/2 universal mount together with VAG1383A transmission hoist). (Scheme 176)

Scheme 175

Scheme 176

Scheme 177

Driving Out Large Tapered Roller Bearing Outer Race

Check adjustment shims for damage after removing.

Scheme 178

Scheme 179

Pressing Large Tapered Roller Bearing Inner Race Onto Drive Pinion

Heat inner race to approx. 100° C, position and press on.

Scheme 180

Pulling In Large Tapered Roller Bearing Outer Race

Insert previously determined adjustment shim "S3" for drive pinion. See DRIVE PINION, ADJUSTING .

Scheme 181

Note. On 3253/4 pressure disc, marking "Oben" points toward nut on installation device.

Pressing In Small Tapered Roller Bearing Outer Race

The outer race must be oiled and installed using VW408A punch and 30-205 thrust pad. (Scheme 183)

Scheme 182

Insert drive pinion with a new spacer sleeve.

Heat up small tapered roller bearing inner race to approx. 100° C and insert on drive pinion.

Press drive pinion upward and insert bearing up to stop using 40-21 sleeve. (Scheme 184)

Scheme 183

Tightening Drive Pinion Nut & Adjusting Friction Torque

Install 3304 retainer using two hex bolts M8 x 30.

When tightening nut, support final drive (e.g. using VAG1359/2 universal mount with VAG1383A transmission hoist). (Scheme 185)

Scheme 184

Always replace drive pinion nut.

Tighten nut for drive pinion until no more drive pinion backlash is present.

Tighten further until specified friction torque is attained; while tightening measure friction torque multiple times. (Scheme 186)

Note. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.

Measuring Friction Torque

Adjust to following friction torque. (Scheme 186) See FRICTION TORQUE ADJUSTMENT table.

Scheme 185

FRICTION TORQUE ADJUSTMENT

Peen drive pinion nut using mandrel. (Scheme 187)

Scheme 186

General Notes

1. Drive pinion and ring gear must be very carefully adjusted to ensure long service life and smooth running. At the factory, drive pinion and ring gear are adjusted relative to each other to ensure smooth running and low noise in both directions. The location for the smoothest running is determined by moving drive pinion axially whereby ring gear is moved far enough out of the backlash-free position so that the backlash is within specified tolerances.
2. The goal of the adjustment is to reproduce the setting for the quietest possible running, as obtained on the test machine during production.
3. The deviation, or tolerance "r" which is based on the master gauge "R0" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. Every drive pinion set - drive pinion and ring gear - may only be replaced together.
4. Follow general repair notes for tapered roller bearings and shims.
5. Make sure that all installation and measurement procedures are performed with the utmost care and cleanliness to ensure a successful result.

Scheme 187

Gear Set, Adjustment Sequence

If drive pinion and gear ring have to be adjusted, the following sequence is recommended for maximum efficiency

1. Determine total shim thickness "Stot" for S1 + S2 for the specified pre-tension of tapered roller bearings for differential.
2. Determine total shim thickness "S3" so that the drive pinion is installed in the same location as on the test machine during production.
3. Distribute total shim thickness Stotal S1 + S2, so that the specified backlash between ring gear and drive pinion is maintained.

Note. Overview of components and adjustment shims. See Adjustment Overview .

Adjustment Overview

Note. When working on transmission, drive pinion or gear set only need to be adjusted if components were replaced which directly influence the final drive. Note the follow table to prevent unnecessary adjustments. (Scheme 189)

Scheme 188

Shim Location

Note. Adjustment overview when replacing individual components of differential. (Scheme 189)

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. VW382/10 extension pin
2. VW385/1 measuring bar
3. VW385/2 centering disc
4. VW385/3 plastic piece
5. VW385/14 measuring rod
6. VW385/15 extension pin
7. VW385/17 magnetic plate
8. VW385/30 master gauge-adjustable
9. VW385/33 end gauge
10. VW387 dial gauge holder
11. VW388 measuring lever
12. VW401 thrust plate
13. VW402 thrust plate
14. VW408A punch
15. VW457 support channels
16. VW521/4 locking sleeve for ring gear
17. VW521/8 bushing for ring gear
18. VW540 holding fixture
19. 30-205 thrust pad
20. 2003/3 seal installer
21. 2052/2 assembly tool for drive pinion
22. 3005 thrust pad
23. 3028 retainer
24. 3062 thrust pad
25. 3253 wheel bearing assembly set with 3253/3 and 3253/4
26. 3304 retainer
27. Engine/transmission jack VAG1383A engine/gearbox jack
28. Dial gauge extension 30 mm
29. Dial gage
30. Torque gauge 0-600 Ncm (Scheme 191)- (Scheme 195).

Adjusting

1. Before adjusting drive pinion, adjust ring gear (determine total shim thickness "S" total" for adjustment shims "S1" + "S2"). See «RING GEAR, ADJUSTING»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__ring-gear-adjusting) .
2. Drive pinion only has to be adjusted again if gear set, tapered roller bearings for drive pinion or final drive housing was replaced. See «Adjustment Overview»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v__adjustment-overview)
3. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.

Determining Shim "S3" (Drive Pinion)

Adjust preload of tapered roller bearing for drive pinion.

Clamp final drive into engine and transmission assembly stand.

Pull large tapered roller bearing outer race into housing. (Scheme 196)

Scheme 195

Note. On 3253/4 pressure disc, marking "Oben" points toward nut on installation device.

Pulling small tapered roller bearing outer race into housing. (Scheme 183)

The outer race must be oiled and installed using VW408A punch and 30-205 thrust pad.

Install drive pinion without spacer sleeve.

Heat up small tapered roller bearing inner race to approx. 100° C and position on drive pinion. (Scheme 184)

1. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
2. Only install spacer sleeve if friction torque has been adjusted (Shim S3 already determined).

Install 3304 retainer using two hex bolts M8 x 30.

When tightening nut, support final drive (e.g. using VAG1359/2 universal mount with VAG1383A transmission hoist). (Scheme 185)

Always replace drive pinion nut.

Tighten nut for drive pinion until no more drive pinion backlash is present.

Increase tightening torque further until specified friction torque is attained; while tightening measure friction torque multiple times.

Adjust friction torque. (Scheme 186) See FRICTION TORQUE ADJUSTMENT table.

Adjust adjustment ring of VW385/1 measuring bar. (Scheme 197)

1. Dimension a = 60 mm.

Scheme 196

Adjust sliding adjustment ring.

1. Dimension b = 55 mm.

Assemble measuring bar as shown in illustration. (Scheme 198)

1. VW385/15 extension pin 9 mm

Scheme 197

Adjust VW385/30 master gauge-adjustable.

1. Ro = 57.50 mm

Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Note. Turn differential at least 5 rotations in each direction to seat the tapered roller bearings. Otherwise, measurement will result in false readings.

Position VW385/33 end gauge on drive pinion head. (Scheme 199)

Scheme 198

Remove master gauge and insert measuring mandrel into housing. (Scheme 200) VW385/3 plastic piece faces final drive cover.

Scheme 199

Install cover for final drive and tighten four bolts.

Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.

Determining Dimension "e" (Drive Pinion)

Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head, and measure the maximum run-out (return point). Measured value is dimension "e" (red numbered area). (Scheme 201)

1. Measured value in the following example: "e" = 1.60 mm

Scheme 200

Note. Dimension "e" is required to determine thickness of S3 shim.

After removing universal mandrel, and with VW385/30 master gauge in place, check dial indicator again to see if it indicates 0, with 2 mm preload. If not, repeat measurement.

Scheme 201

Scheme 202

Determine shim as closely as possible according to table. (Scheme 204)

Scheme 203

Remove universal mandrel.

Remove drive pinion and large tapered roller bearing outer race and install together with determined adjustment shim "S3" and spacer sleeve. See Tools For Removing & Installing Drive Pinion Nut .

Insert small tapered roller bearing inner race and tighten nut for drive pinion until specified friction torque is attained. (Scheme 185)

Note. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory. Increase torque slowly and measure friction torque multiple times. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.

Adjust friction torque to values in FRICTION TORQUE ADJUSTMENT table.

Checking dimension "r" (Drive Pinion)

Rotate drive pinion at least 5 complete revolutions in both directions.

Insert universal mandrel and perform check measurement. (Scheme 205)

Scheme 204

1. If adjustment shims were determined correctly, dial indicator must indicate deviation "r" with a tolerance of +/- 0.04 mm (reading counterclockwise in red number display).

Peen drive pinion nut using mandrel. (Scheme 187)

RING GEAR, ADJUSTING

Adjusting differential.

Procedures after which the ring gear must be adjusted. See Adjustment Overview .

Note. Tapered roller bearings for differential are low-friction bearings. Therefore friction torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "Sges". Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.

Total Shim Thickness "Stotal" For Adjustment Shims "S1" + "S2", Determining

Adjust preload of tapered roller bearing for differential.

1. Drive pinion removed or ring gear detached from differential housing.

Pry out drive flange seal using tire iron.

Remove tapered roller bearings for differential and remove adjustment shims. See DIFFERENTIAL .

Press tapered roller bearing outer race for left side of differential housing (housing side) together with shim "S2" into differential housing (Scheme 156). Use a shim "S2*" with a 1.00 mm thickness for measurement purposes (1 shims with 0.80 and 1 with 0.20 mm).

Note. All measurements are performed with shim S2 with 1.00 mm thickness. The shim will be indicated by "S2*" in the following procedures. After determining backlash, S2* is replaced by final shim S2.

Press in tapered roller bearing outer race for right side (cover side) of differential without adjustment shims to stop. (Scheme 163)

Insert differential in housing. Ring gear is on the right side (cover side).

Install cover and tighten bolts to 25 Nm.

Install VW521/4 locking sleeve and 521/8 sleeve press tool into differential housing on housing side. (Scheme 206)

Scheme 205

Rotate cover side of differential housing upward.

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Place VW385/17 magnetic plate onto differential.

Install measuring tools. (Scheme 207)

Scheme 206

Set dial gauge extension onto center of VW 385/17 magnetic plate.

Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Lift the differential without turning it, read play on dial indicator and note. (Scheme 208)

Scheme 207

1. Measured value in the following example: 0.50 mm

Note. If measurement is repeated, differential must first be rotated 5 complete revolutions in both directions again to seat tapered roller bearing.

Scheme 208

Determining Thickness Of Shim "S1*" (Ring Gear)

Note. "S1*" is used for the initial measurement. After determining backlash, "S1*" is replaced with final shim "S1". The total shim thickness "Stotal" remains unchanged.

Determine adjustment shim(s) as closely as possible according to table. see scheme 103

Measuring Friction Torque (Check Measurement)

1. Drive pinion removed
2. Differential installed with shims "S1*" and "S2*"

Position torque gauge 0 to 600 Ncm -A- on differential. (Scheme 211)

Scheme 209

Read friction torque.

Friction torque specified values. See RING GEAR FRICTION TORQUE table.

RING GEAR FRICTION TORQUE

1. Tapered roller bearings for differential are low-friction bearings. Therefore friction torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "Sges".
2. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
3. For a new adjustment of the gear set, the drive pinion adjustment should now be checked. See «DRIVE PINION, ADJUSTING»(/audi/a4/b5-1994-1999/remont/automatic-trans/#overhaul-01v) .

Adjusting Backlash

Position of ring gear in transmission housing.

1. Drive pinion installed with shim S3
2. Differential installed with shims "S1*" and "S2*"

Insert differential into final drive housing, install cover and tighten all bolts to 25 Nm.

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Install measuring tools. (Scheme 212)

Scheme 210

Use VW382/10 extension pin, 6 mm.

Set VW388 measuring lever to dimension "a" = 60 mm.

Determine backlash between teeth flanks as follows

1. Turn ring gear until it contacts a tooth flank (end of backlash travel).
2. Set dial indicator to 0 with 1 mm preload.

Turn ring gear back until it contacts opposite tooth flank (backlash).

Read backlash and note.

Turn ring gear an additional 90° in each case and repeat measurement 3 times.

Note. If measurements vary more than 0.06 mm from each other, ring gear or gear set is not installed correctly. Check installation, replace gear set if necessary.

Determining Average Backlash

To determine average backlash (Scheme 213)

Scheme 211

Determining Thickness Of Shim "S2" (Ring Gear)

Determine shim as closely as possible according to table. (Scheme 214)

Scheme 212

Scheme 213

Determining Thickness Of Shim "S1" (Ring Gear)

Determine shim as closely as possible according to table. see scheme 103

Scheme 214

Scheme 215

Checking Measurement (Ring Gear)

1. Drive pinion installed with shim S3
2. Differential installed with shims "S1" and "S2"

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Measure backlash 4 times on circumference. (Scheme 212)

1. Specification: 0.12 to 0.22 mm

Note. If backlash is outside tolerance, repeat adjustments. Do not change total shim thickness "Stotal" while doing so. The individual measurement values can deviate a maximum of 0.06 mm from each other.

See also:
• SERVICING - A/T (01V - WITH 1.8L, 2.7L & 2.8L
• AXLE SHAFTS - FRONT & REAR
• REMOVAL & INSTALLATION - A/T (01V - WITH 1.8L & 2.8L)
• CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT
• RULES OF CLEANLINESS FOR WORKING ON AUTOMATIC TRANSMISSIONS
• REPAIR INSTRUCTIONS
• Adjusting Differential Bevel Gears
• Adjustment Overview
• RING GEAR, ADJUSTING