Clutches - 01a, Awd Audi A4 B5

TRANSAXLE

This article applies to 1996-2001 A4 models with All Wheel Drive.

The manual transmission 01A AWD is installed in the Audi A4 as a 5-speed transmission in conjunction with the 4-cylinder turbo engine or 6-cylinder engine.

Note. The code letters of the transmission are engraved on the lower part of the transmission cover and are also engraved on the vehicle data plates.

For identification locations on transaxle, see list below.

1. Code letters and date of manufacture (arrow 1). (Scheme 56)
2. Manual transmission 01A (arrow 2). (Scheme 56)
3. Code letters (arrow 3). (Scheme 56)
4. Code letters and date of manufacture (arrow). (Scheme 57)

Scheme 56

Scheme 57

DESCRIPTION

Clutch is a single-disc type, using a diaphragm spring to engage pressure plate. Clutch is hydraulically-controlled by master cylinder, slave cylinder, release lever and pre-lubricated release bearing. Clutch master cylinder is supplied fluid from brake master cylinder fluid reservoir. Vehicles are equipped with a dual-mass flywheel.

CLUTCH HYDRAULIC SYSTEM OVERVIEW

To identify CLUTCH HYDRAULIC SYSTEM components. (Scheme 58)

Scheme 58

CLUTCH HYDRAULIC SYSTEM

Note. When carrying out the following steps, make sure that no brake fluid escapes onto the transmission. The clutch system must be bled after carrying out work on the hydraulic clutch mechanism. Top off brake fluid reservoir to "MAX." mark with brake fluid before bleeding clutch system.

Note. Use only fresh brake fluid conforming to US standard FMVSS 116 DOT 4. Genuine VW/Audi brake fluid conforms to this specification.

Note. While bleeding, make sure bleeder hose remains correctly routed.

1. Pull clutch pedal back to rest position. Connect brake filler/bleeder unit VAG 1238B or VAG1869, but do not switch on. Connect bleeder hose A to clutch slave cylinder (arrow) and open bleeder valve. (Scheme 59)
2. Connect bleeder hose with pressure hose to collector bottle. Switch on bleeding appliance and let approximately 100 cm 3 (approx. 3.4 fl. oz.) brake fluid flow into suitable collection reservoir. Work pressure: 2.5 bar (36 psi).
3. Close bleeder valve. Tightening torque: 40 in. lbs. (4.5 N.m). Depress clutch pedal several times after completion of bleeding process. Bleed system again if necessary.

Scheme 59

CLUTCH PEDAL FREE PLAY

Note. Hydraulic clutch systems are automatically adjusted and require no manual adjustment.

CLUTCH PEDAL POSITION SWITCH

Note. Switch is installed from 5/1997.

Scheme 60

1. Loosen two bolts slightly (arrows). (Scheme 60)
2. Have second technician fully depress clutch pedal up to stop. Place feeler gauge A with specific dimension "a", 3.2 mm +/- 0.2 mm (0.126 in. +/- 0.008 in.), between operating surface of clutch pedal and switch cam. (Scheme 60)
3. Move switch B toward gauge A until stop, and tighten two mounting bolts (arrows) to 8 N.m (71 INCH lbs). (Scheme 60)

Adjusting

The following points are essential to ensure correct selector adjustment

1. Moving parts of selector mechanism and transaxle elements must be in proper condition.
2. Selector mechanism must move freely.
3. Transaxle, clutch and clutch mechanism must also be in proper condition.

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Place gearshift selector in Neutral position. Carefully remove shift boot from center console. (Scheme 61) Remove gearshift knob and boot. Remove 2 nuts and rubber cover from gearshift selector housing.
2. Measure distance between body and selector mechanism. (Scheme 62) Distance "a" must be 1. 46" (37 mm). If measurement is not as specified, adjust dimension a.
3. Loosen push rod bolt. Connection push rod/selector mechanism must move freely. Set to dimension "a", by moving selector mechanism. (Scheme 63) Tighten slide rod bolt to 17 ft. lbs. (23 N.m).
4. Loosen ball housing nuts (A and B). (Scheme 64) Set ball housing so it is horizontal. Tighten ball housing nut (A) to 18 ft. lbs. (25 N.m). Tighten ball housing nut (B) to 84 INCH lbs. (10 N.m).
5. Loosen selector rod bolt (arrow). (Scheme 65) Connection selector rod/selector mechanism must move freely. Align shift lever so it is positioned slightly toward rear.
6. Dimension a between ball stop buffers and ball housing should be equal on both sides. (Scheme 66) Have second technician hold shift lever. Tighten bolt for shift rod to 17 ft. lbs. Nm (23 Nm).

Shift Mechanism Adjustment (Checking)

1. Shift lever must rest in 3rd/4th gear gate when transaxle is in Neutral. Operate clutch. Make sure all gears can be engaged properly.
2. Check operation of reverse gear lock. Move shift mechanism into 5th/reverse-gear gate and move in direction of reverse gear (do not push shift lever too hard).
3. The movement up to stop reverse-gear lock must be 5-10 mm (0.196-0.394 in.) measured at shift knob. Reduce pressure on shift lever, so it can move back. Shift lever should return by itself from the 5th/reverse gear gate and move into 3rd/4th gear gate.
4. Check fine adjustment if necessary. See «SHIFT MECHANISM ADJUSTMENT: FINE ADJUSTMENT»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd__shift-mechanism-fine-adjustment) .

Shift Mechanism (Fine Adjustment)

1. Loosen nuts for ball housing (arrows A and B). (Scheme 64) Move shift lever together with ball housing to right toward 5th/reverse gear gate up to stop in transmission and hold in position. Press ball housing to left against shift lever.
2. Hold shift lever and ball housing in position. Tighten ball housing nut (A) to 18 ft. lbs. (25 N.m). Tighten ball housing nut (B) to 84 INCH lbs. (10 N.m). Install covers and shift knob. NOTE: If only 5th gear and reverse gear cannot be engaged, the 5th and reverse gear lock must be checked and replaced if necessary. See «REMOVING & INSTALLING: GEAR LOCK FOR FIFTH & REVERSE GEAR»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).

Scheme 66

1. Remove heat shield (arrow 2) above right drive axle. (Scheme 67) Detach heat shield (arrow 1) above right drive axle and pivot downward. (Scheme 67)
2. Remove gear lock (arrow). (Scheme 68)

Scheme 67

Scheme 68

Scheme 69

1. Insert spring 1 into housing 2 and, while applying light pressure, turn spring to left until it locates in base of housing. (Scheme 69)
2. Insert bushing 3 onto spring so bent end of spring locates into groove properly. (Scheme 69)
3. Push bushing against spring and turn approx. one turn to left, until lug on bushing aligns with groove in housing.
4. Press lug of bushing into groove in housing onto stop.
5. Turn bushing to right and release. The bushing will spring into the correct position.
6. Installation position of bushing: Lug (arrow A) of bushing must always face away from groove in housing (arrow B). (Scheme 70)
7. Checking installation position: Turn bushing to left and release. The bushing should spring back into position; the lug must be against the stop, (direction indicated by arrow A). (Scheme 70)
8. Installation position of complete gear lock in transmission: The recess (arrow A) faces bolt (arrow B). (Scheme 71)

BATTERY DISCONNECT PRECAUTIONS

If connector is disconnected from ECM or the battery is disconnected, all adaptation values in control module are erased. DTC memory content will remain intact however. If engine is started after this, a rough, uneven idle can result. In this case, engine must be allowed to run at idle for a few minutes or a longer road test must be performed until adaptation procedure has been completed.

Once battery has been connected, check operation of radio, clock and convenience electronics. Completely open and close all power windows.

Note. Vehicles with On Board Diagnostics (OBD) II must have readiness code for Electronic Control Module (ECM) re-generated after battery has been disconnected. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

CLUTCH PEDAL ASSEMBLY & CLUTCH CONTROL OVERVIEW

To identify components not found in the REMOVAL & INSTALLATION procedures. (Scheme 72)and (Scheme 73).

Scheme 70

Scheme 71

CLUTCH MASTER CYLINDER

Note. On models with theft protection system, obtain radio security code from vehicle owner before disconnecting battery cable.

Removal

Turn ignition switch to OFF position. Disconnect negative battery cable. See BATTERY DISCONNECT PRECAUTIONS .

Scheme 72

Scheme 73

Scheme 74

1. Remove E-box from plenum chamber: Remove bolts (arrows) and remove cover. (Scheme 74) Remove Engine Control Module (ECM). If necessary, remove 8-pin relay support.
2. Disconnect harness connectors at connector station. Remove engine wiring harness together with rubber grommet from opening in E-box.
3. Remove both nuts A. (Scheme 75) Lift E-box out at rear of threaded bolt and remove from mounting point B. (Scheme 75)
4. Clamp supply hose A from brake fluid reservoir using 3094 hose clamp. (Scheme 76) Pull hose off clutch master cylinder and plug hose. Disconnect line B from clutch master cylinder and seal. (Scheme 76)
5. Remove driver's side storage compartment. Remove clutch pedal position switch if installed. (Scheme 60)
6. Unclip master cylinder pivot pin using screwdriver (arrow 1) (Scheme 77), pull out pin (arrow 2). Detach clutch pedal from clutch master cylinder.
7. Unbolt clutch master cylinder from passenger compartment.

Scheme 75

1. Installation is the reverse of removal. When replacing clutch master cylinder, check dimension a on ball head and adjust if necessary. Dimension a = 165 +/- 0.5 mm (6.496 +/- 0.020 in.). (Scheme 78)
2. Connect clutch master cylinder to clutch pedal. Secure pin and locking plate on clutch pedal. Tighten line fitting B to clutch master cylinder to 15 N.m (11 ft. lbs.). (Scheme 76)
3. Slide hose A onto brake fluid reservoir up to stop. (Scheme 76) Bleed hydraulic clutch system after installing clutch master cylinder. See «BLEEDING»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).
4. Install E-box in plenum chamber, always replace seal C. (Scheme 75) Make sure seal is positioned properly, and does not cover opening or stepped metal edge. Install E-box into mounting point B. (Scheme 75) Tighten nuts A to 35 INCH lbs. (4 N.m). Install cap and hand tighten in diagonal sequence to 35 INCH lbs. (4 N.m).

CLUTCH SLAVE CYLINDER

Note. Do not press clutch pedal after clutch slave cylinder has been removed.

Disconnect and plug fluid line. Remove bracket 3 for pressure line 1. (Scheme 79) Remove clutch slave cylinder from bore of transmission housing.

Scheme 76

Scheme 77

1. Before installing, coat contact surface of clutch release lever plunger with thin layer of copper grease (e.g. Z 381 351 TE). (Scheme 80) Before installing clutch slave cylinder in transmission, coat boot area a with G 052 150 A2 lithium grease. (Scheme 80)
2. Guide clutch slave cylinder into bore of transmission housing without large sideways deviation from direction of motion of plunger. Attach bracket 3 for pressure line 1. (Scheme 79)
3. Pre-load the clutch slave cylinder enough so that the mounting bolt can be easily installed. Install mounting bolt 2. (Scheme 79)
4. If mounting bolt 2 is a hex bolt install with D 185 400 A2 locking fluid and tighten to 18 ft. lbs. (25 N.m). (Scheme 79) If socket-head bolt is used, it is self-locking: always replace and tighten to 15 ft. lbs. (20 N.m).
5. Bleed system at slave cylinder. See «BLEEDING»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. Remove driver's side storage compartment. (Scheme 82) If installed, remove switch above clutch pedal.
2. Unclip pin and locking plate using screwdriver (arrow 1), remove pin and locking plate (arrow 2), and detach clutch pedal from clutch master cylinder. (Scheme 83) Press locking clip for clutch pedal off pivot pin using screwdriver.
3. Remove bolt (arrow). See. Press clutch and brake pedal pivot pin out toward right, until clutch pedal can be removed. If necessary, press locking clip for brake pedal off pivot pin using screwdriver. Remove clutch pedal and over-center spring. (Scheme 84)

Scheme 82

1. Installation is the reverse of removal, note the following: Align pivot pin so that it protrudes out of mounting bracket on clutch pedal side (arrow). (Scheme 85) Hook clutch pedal into over-center spring, then install onto pivot pin. Connect clutch pedal to master cylinder. Clip locking pin onto clutch pedal.
2. Do not tighten bolt (arrow) until both securing clips have been installed on pivot pin. (Scheme 84)

CLUTCH RELEASE MECHANISM OVERVIEW

To identify CLUTCH RELEASE MECHANISM components. (Scheme 86)

Scheme 83

CLUTCH ASSEMBLY

Note. On models with theft protection system, obtain radio security code from vehicle owner before disconnecting battery cable.

Note. If there are white spots on the dual mass flywheel (A) and pressure plate (B), make sure that they line up when you assemble them (if reusing original parts). (Scheme 89)

Turn ignition switch to OFF position. Disconnect negative battery cable. See BATTERY DISCONNECT PRECAUTIONS . Remove transaxle. See TRANSAXLE . Loosen pressure plate bolts gradually, in a crosswise pattern. Remove pressure plate and clutch disc.

Inspection

Note. Pressure plate has a protective grease coating. Remove contact surface grease only. Service life will be shortened if remaining portions of pressure plate protective grease are removed.

Scheme 84

1. Inspect pressure plate surface for wear, cracks, burning or warpage. Inspect pressure plate diaphragm spring for wear. (Scheme 87) Up to half thickness of diaphragm spring is permitted.
2. Inspect clutch release bearing for smooth operation and looseness. DO NOT wash release bearing in solvent. Replace bearings if noisy.
3. Inspect clutch disc lining for excessive wear and burned or oil-soaked condition. Checking spring connection and rivets. Check spring connection between pressure plate and cover for cracks and make sure rivets are seated tightly. Replace clutches with damaged springs or loose rivets (arrows). (Scheme 88)
4. Inspect flywheel ring gear teeth for wear and damage. Inspect flywheel for wear, cracks and burned condition. If flywheel needs service or replacement. See Inspect pilot bearing. If pilot bearing needs replacing, see «DUAL-MASS FLYWHEEL, PILOT NEEDLE BEARING»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).

Installation

1. To install, reverse removal procedure. Clean input shaft splines and on used clutch plates, hub splines, remove corrosion and apply only a very thin coating of grease (G 000 100) to input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely on shaft. Excess grease must be removed.
2. Installation position of clutch plate: Spring pack (coil springs) facing pressure plate. Clutch lining must make full contact with flywheel. Marking "Getriebeseite" (if provided) faces pressure plate.
3. Make sure centering pins are in place and seated correctly. Contact surface for clutch lining must be free of dirt, oil and grease.
4. Install pressure plate bolts finger tight. Using clutch centering tool (3176), align clutch disc and pilot bushing holes. (Scheme 90) Tighten pressure plate bolts to specification using a crosswise pattern. Install transaxle. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).

Scheme 85

1. Remove pilot needle bearing using puller A (e.g. KUKKO 21/2 and KUKKO 22/1). (Scheme 91) Install pilot needle bearing using 3264 bearing driver.
2. On 2.8L V6 engine: With crankshaft at Top Dead Center (TDC), install 3242 crankshaft holder. (Scheme 92) Mark position of dual-mass flywheel and engine housing (arrows). (Scheme 92) Remove dual-mass flywheel bolts.
3. On, 2.8L V6 engine: With crankshaft at Top Dead Center (TDC), install 3242 crankshaft holder (2.8L V6 engine). (Scheme 92) Marks on dual-mass flywheel and engine housing (arrows). Install dual-mass flywheel bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).
4. On 1.8L engine: Install 10-201 flywheel retainer to loosen and tighten bolts. (Scheme 93) Mark installed position (flywheel to crankshaft) to reinstall in same position. Install dual-mass flywheel bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).

For special tool identification (Scheme 94)

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

1. Turn ignition switch to OFF position. Disconnect battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd__battery-disconnect-precautions).
2. Disconnect wires/and harness connectors as follows: 1 - Solenoid valve for wastegate bypass regulator valve 2 - EVAP canister purge regulator valve 3 - Power output stage 4 - Mass Air Flow (MAF) sensor
3. Disconnect hoses and remove air cleaner housing (arrows). (Scheme 95) Remove coolant expansion tank from bracket and lay to side.
4. Disconnect harness connector for Heated Oxygen Sensor (HO2S) (arrow) and move wiring clear. (Scheme 96)
5. Remove engine/transaxle mounting bolts accessible from above. Remove noise insulation panel (arrows). (Scheme 97)
6. Remove bracket for noise insulation panel (arrow). (Scheme 98)
7. Remove heat shield (arrows 1 and 2) above right drive axle. (Scheme 99)
8. Unbolt right transaxle support together with bonded rubber mount (arrows). (Scheme 100) Loosen clamping sleeves of exhaust system and slide toward Three Way Catalytic Converter (TWC). Remove Three Way Catalytic Converter (TWC) together with exhaust pipe from below.
9. Remove nuts securing turbocharger to front exhaust pipe. Remove intake hose from air mass sensor.
10. Remove engine/transaxle mounting bolts accessible from above. Remove noise insulation panel (arrows). (Scheme 97)
11. Remove bracket for noise insulation panel (arrow). (Scheme 98) Remove heat shield (arrows 1 and 2) above right drive axle. (Scheme 99)
12. Unbolt right transaxle support together with bonded rubber mount (arrows). (Scheme 100)
13. Loosen clamping sleeves of exhaust system and slide toward Three Way Catalytic Converter (TWC). Remove Three Way Catalytic Converter (TWC) together with exhaust pipe from below. Remove engine speed (RPM) sensor on left of transaxle (arrow) and move clear to side. (Scheme 101)
14. Disconnect drive axles from flange shafts and rest them on suspension links.
15. Disconnect harness connector from Vehicle Speed Sensor (VSS) (arrow A). (Scheme 102) Disconnect back-up light harness connector, (multi-function switch), (arrow B). (Scheme 102)
16. Disconnect all other electrical connections and Ground (GND) wires from transaxle and from engine/transaxle mounting bolts. Remove starter from engine/transaxle and secure if necessary. (Scheme 103)
17. Disconnect shift rod (arrow A). (Scheme 104) Remove socket-head bolt from pivot rod (arrow B). (Scheme 104)
18. Remove heat shield for driveshaft from Torsen differential cover (arrows). (Scheme 105)
19. Remove driveshaft 1 from transaxle and rest it on heat shield 2. Secure driveshaft to fuel line bracket 3 using wire (arrow). (Scheme 106)
20. Remove bottom engine/transaxle mounting bolts, EXCEPT for bolts indicated by arrows A and B. (Scheme 107)
21. Set up the transmission support 3282 for removing the manual transmission with adjustment plate 3282/10 and attach to transmission lifter VAG 1383A transmission jack. (Scheme 108)
22. Roll VAG1383A transmission jack with 3282 transmission support under transaxle and support transaxle. (Scheme 109)
23. Support transaxle using VAG1383A transmission jack. Align adjustment plate parallel to transaxle and lock safety support (arrow) on transaxle. (Scheme 110)
24. Remove left transaxle support from bonded rubber mount 2. (Scheme 111)
25. Remove remaining engine/transaxle mounting bolts (arrows A and B). (Scheme 107) Press transaxle off dowel sleeves and lower carefully using VAG1383A transmission jack just far enough for access to slave cylinder.
26. Remove clutch slave cylinder (arrow) and secure using wire; do not disconnect line. (Scheme 112)
27. Lower transaxle completely.

Scheme 99

Scheme 100

Scheme 101

1. Turn ignition switch to OFF position. Disconnect negative battery cable. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd__battery-disconnect-precautions).
2. Remove intake air duct A (arrows). (Scheme 113) Unbolt coolant expansion tank B (arrows) and lay to one side. (Scheme 113) Remove Heated Oxygen Sensors (HO2S) on left and right exhaust pipes using 3337 ring spanner 7-piece set and move clear to side.
3. Remove engine/transaxle mounting bolts accessible from above. Remove noise insulation panel (arrows). (Scheme 97)
4. Remove bracket for noise insulation panel (arrow). (Scheme 98)
5. Remove heat shields above left and right drive axles. Unbolt front exhaust pipes together with Three Way Catalytic Converters (TWCs) from left and right exhaust manifolds (3 nuts on each side) (arrows). (Scheme 114)
6. Remove engine speed (RPM) sensor on left of transaxle (arrow) and move clear to side. (Scheme 101)
7. Disconnect drive axles from flange shafts and rest them on suspension links.
8. Disconnect harness connector from Vehicle Speed Sensor (VSS) (arrow A). (Scheme 102) Disconnect back-up light harness connector, (multi-function switch), (arrow B). (Scheme 102)
9. Disconnect all other electrical connections. Disconnect Ground (GND) wires from transaxle and engine/transaxle mounting bolts. Remove starter from engine/transaxle and secure if necessary. (Scheme 103)
10. Disconnect shift rod (arrow A). (Scheme 104) Remove socket-head bolt from pivot rod (arrow B). (Scheme 104)
11. Remove heat shield for driveshaft from Torsen differential cover (arrows). (Scheme 105) Remove driveshaft 1 from transaxle and rest it on heat shield 2. Secure driveshaft to fuel line bracket 3 using wire (arrow). (Scheme 106)
12. Remove bottom engine/transaxle mounting bolts, EXCEPT for bolts indicated by arrows A and B. (Scheme 107)
13. Set up the transmission support 3282 for removing the manual transmission with adjustment plate 3282/10 and attach to transmission lifter VAG 1383A transmission jack. (Scheme 108)
14. Roll VAG1383A transmission jack with 3282 transmission support under transaxle and support transaxle. (Scheme 109)
15. Support transaxle using VAG1383A transmission jack. Align adjustment plate parallel to transaxle and lock safety support (arrow) on transaxle. (Scheme 110)
16. Remove left and right transaxle supports complete with bonded rubber mounts from transaxle and subframe 1 and 2. (Scheme 115)
17. Remove remaining engine/transaxle mounting bolts (arrows A and B). (Scheme 107) Press transaxle off dowel sleeves and lower carefully using VAG1383A transmission jack just far enough for access to slave cylinder.
18. Remove clutch slave cylinder (arrow) and secure using wire, DO NOT disconnect line. (Scheme 112)
19. Lower transaxle completely.

Installation: 1.8L Turbo & 2.8L V6, All Wheel Drive

1. Clean input shaft splines and (in case of used clutch plates) hub splines. Remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
2. Check throw out bearing for wear and replace if necessary. Before installing, coat contact surface of clutch release lever plunger with thin layer of copper grease, e.g. Z 381 351 TE.
3. Threaded holes for mounting clutch slave cylinder to transaxle and shift lever to shift rod must be cleaned of locking compound residue using threaded tap before installation.
4. Check whether dowel sleeves for aligning engine/transaxle are installed correctly in cylinder block, install or replace if necessary.
5. Always replace self-locking nuts.
6. Ensure intermediate plate (if installed) is correctly positioned on engine.

Scheme 102

1. Lift transaxle until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow). (Scheme 112)
2. Install lower engine/transaxle and starter mounting bolts and install starter.
3. Before installing, use tap to clean threads in flange shaft for driveshaft on transaxle to remove traces of locking compound. Replace gaskets on drive axles and on front of driveshaft.
4. Aligning mating marks made during removal, install driveshaft to transmission flange. See «DRIVESHAFT»(/audi/a4/b5-1994-1999/remont/driveshaft-universal-joints/#driveshaft-universal-joints) article.
5. Check adjustment of shift mechanism and adjust if necessary. See «SHIFT MECHANISM»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd).
6. On 1.8L engines, align exhaust system free of stress. See «ALIGNING EXHAUST SYSTEM»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd__aligning-exhaust-system).
7. Check transaxle oil level. The oil filler plug is on left side of the transaxle underneath the engine speed (RPM) sensor, and may be concealed by a heat shield over the drive axle. Depending on the version installed, use either 3357 triple square socket driver or a 17 mm hex socket to loosen the oil drain plug. see scheme 61
8. To check oil level, remove oil filler plug (arrow). see scheme 62 Check oil level with hand-made tool (e.g. bent wire). Specification: Oil 0.276 in. (7 mm) below bottom of filler hole. Using gear oil: SAE 75 W 90 (synthetic oil), part number G 005 000 (1 liter) top off transmission oil if necessary. Install oil filler plug. Tightening torque: 18 ft lb. (25 N.m). see scheme 62: Locating Oil Filler Plug
9. Ensure all fasteners are tightened to specifications. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/clutches-manual-hydraulic/#clutches-01a-awd). On 2.8L V6, oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings. Tighten oxygen sensor to 37 ft. lbs. (50 N.m).
10. Connect battery. After connecting battery, enter anti-theft code for radio. Fully close power windows to window stop, then activate all power window switches ("up") for at least a second to activate automatic window raising/lowering. Set clock to correct time.

Securing Transaxle To Assembly Stand: All Wheel Drive

Secure transaxle to assembly stand using VW353 transmission support and VW309 holding plate when working on transaxle. see scheme 63

Scheme 103

Scheme 104

Scheme 105

1. The transaxle support jig can be used when transporting the transaxle and for setting up 3282 transmission support.
2. Bolt 3336 transmission support jig to transaxle housing. see scheme 64
3. Adjust support jig on sliding piece using locking pin, seventeen holes should be visible (arrow). see scheme 65
4. Lift transaxle using workshop crane and 3336 transmission support jig. see scheme 65

Aligning Exhaust System

Align exhaust so components are free of stress.

Aligning Exhaust System: 1.8L (Engine Codes AEB & ATW)

Note. After exhaust system repairs or reinstallation, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and align muffler and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.

All Wheel Drive Vehicles: Without Double Clamp Between Front And Rear Mufflers.

Note. There is a double clamp located at the front of front muffler pipe. There is no double clamp between front and rear mufflers.

Scheme 106

Scheme 107

Scheme 108

1. Align exhaust system when cold. Double clamp is located at the front of the front muffler pipe. Remove double clamp bolts. Push exhaust system forward (arrow) until tension on rear mount equals dimension a in see scheme 66. Dimension a is 0.275-0.433 in. (7-11 mm).
2. Before tightening double clamp, ensure exhaust system is free of stress. Double clamp installation position: Bolt ends point toward left. Bolt ends should not project over lower edge of double clamp. see scheme 67 Tighten evenly to 30 ft. lbs. (40 N.m).
3. Align tailpipes so distance a on left and right side is equal. Distance b between bumper cutout and tailpipes must equal specification: Distance b is 1.57-1.81 in. (40-46 mm). see scheme 68

All Wheel Drive Vehicles: With Double Clamp Between Front And Rear Mufflers

Note. Only for vehicles with double clamp between front and rear mufflers

Note. There is also a double clamp located at the front of front muffler pipe.

Scheme 109

1. Align exhaust system when cold. Remove double clamp bolts. Push exhaust system forward (arrow) until initial preload on left rear mount equals dimension a. see scheme 69 Dimension a is 0.275-0.354 in. (7-9 mm). Tighten front double clamp bolts evenly to 30 ft. lbs. (40 N.m).
2. Push exhaust system forward (arrow) until initial preload on right-rear mount equals dimension a. see scheme 66 Dimension a is 0.275-0.433 in. (7-11 mm). Tighten rear double clamp bolts evenly to 30 ft. lbs. (40 N.m).
3. Align tailpipes so distance a on left and right side is equal. Distance b between bumper cutout and tailpipes must equal specification. see scheme 68 Distance b is 1.614-1.850 in. (41-47 mm).

Exhaust System: Checking For Leaks

1. Start engine and run at idle. Seal tailpipes with cloths or equivalent for duration of leak test.
2. Listen for leaks at following connections: Cylinder head/exhaust manifold, exhaust manifold/turbocharger, turbocharger/Three Way Catalytic Converter (TWC), etc. Repair leaks as necessary.

Information not available from manufacturer.

Information not available from manufacturer.

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

See also:
• DRIVESHAFT
• SHIFT MECHANISM ADJUSTMENT: FINE ADJUSTMENT
• REMOVING & INSTALLING: GEAR LOCK FOR FIFTH & REVERSE GEAR
• BATTERY DISCONNECT PRECAUTIONS
• ALIGNING EXHAUST SYSTEM