Servicing - M/t (5-speed, 01a) Audi A4 B5

TRANSAXLE

This article applies to 1996-2001 A4 models with the 01A with all wheel drive.

The AWD manual transmission 01A 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 68)
2. Manual transmission 01A (arrow 2). (Scheme 68)
3. Code letters (arrow 3). (Scheme 68)
4. Code letters and date of manufacture (arrow). (Scheme 69)

Scheme 68

Scheme 69

SERVICE INTERVALS

No oil changes are required.

CHECKING FLUID LEVEL

The oil filler plug is on the left of the transmission below the speedometer vehicle speed sensor and may be concealed by the heat shield for the drive axle.

Depending on the version installed, use either 3357 triple square socket driver or a 17 mm to loosen the oil filler plug.

Remove oil filler plug. (Scheme 70) Oil level should be up to lower edge of filler hole. Add if necessary. Install filler plug and tighten to 18 ft. lbs. (25 N.m). When filling with NEW oil, remove plug (arrow). For recommended fluid, see RECOMMENDED FLUID. Top off oil to lower edge of filler hole. Install filler plug.

Scheme 70

RECOMMENDED FLUID

Manufacturer recommends API 75W-90, G50 synthetic gear oil.

FLUID CAPACITIES

TRANSMISSION REFILL CAPACITIES

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.

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 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. Place gearshift selector in Neutral position. Carefully remove shift boot from center console. Remove gearshift knob and boot. Remove 2 nuts and rubber cover from gearshift selector housing. (Scheme 71)
2. Measure distance between body and selector mechanism. (Scheme 72) Distance -a- must be 1. 46" (37 mm). If measurement is not as specified, adjust distance -a-.
3. Loosen bolt for pivot rod (arrow -2-). (Scheme 73) Rear pivot rod (in shift mechanism) should move freely in both directions on slide. Adjust distance -a- by moving pivot rod. Tighten pivot rod bolt. Tightening torque: 17 ft. lbs. (23 N.m).
4. Loosen ball housing nuts (A and B). (Scheme 74) Align ball housing horizontally. 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 75) 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. see scheme 9 Have second technician hold shift lever. Tighten bolt for shift rod to 17 ft. lbs. Nm (23 Nm).

Shift Linkage 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 0.196-0.394 in. (5-10 mm) 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 (FINE ADJUSTMENT)»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__shift-linkage-fine-adjustment) .

Shift Linkage (Fine Adjustment)

1. Loosen nuts for ball housing (arrows A and B). (Scheme 76) 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/manual-trans/#servicing-mt-5-speed-01a).

Scheme 76

1. Remove heat shield (arrow 2) above right drive axle. (Scheme 77) Detach heat shield (arrow 1) above right drive axle and pivot downward. (Scheme 77)
2. Remove gear lock (arrow). (Scheme 78)

Scheme 77

Scheme 78

Scheme 79

1. Insert spring 1 into housing 2 and, while applying light pressure, turn spring to left until it locates in base of housing. (Scheme 79)
2. Insert bushing 3 onto spring so bent end of spring locates into groove properly. (Scheme 79)
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 80)
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 80)
8. Installation position of complete gear lock in transmission: The recess (arrow A) faces bolt (arrow B). (Scheme 81)

REMOVAL & INSTALLATION

AXLE SEALS

Note. Transmission code CXF: Drive flanges are installed without polygon bearings.

Note. This procedure is performed with transmission installed. The following procedure is for removal and installation of the left seal. The same procedure is used for the left and right seals. The exhaust system need not be removed.

Scheme 80

1. Remove heat shield for drive axle.
2. Remove drive axle from transmission drive flange. For more information, see «AXLE SHAFTS - FWD & AWD»(ref-161308) article.
3. Turn steering as far to left as possible. Tie up drive axle as high as possible. Do not damage paint on drive axle. Place VAG1306 drip tray under transmission.
4. Have second technician hold two tire irons -2- under drive flange. (Scheme 82) To remove drive flange, install two bolts -1- evenly into two opposite bores in drive flange. (Scheme 82)
5. Always replace circlip for drive flange. Clamp drive flange into vise using protective jaws. Press circlip out of groove in drive flange by pressing in new circlip -A-. (Scheme 83)
6. Remove drive flange seal using VW681 extractor lever.
7. If polygon (needle) bearings are used, check them for cracks, excessive wear and damage. (Scheme 84)

Installation

Note. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Lubricate area between sealing lip and dust lip with a thin layer of multi-purpose grease. Lightly oil outer circumference of seal. Drive in new right-hand drive flange seal 5.5 mm (0.217 in.) below transmission housing surface, without canting. (Scheme 85)
2. Drive in drive flange using VW295 needle bearing drift. Bolt drive axle to drive flange. Install heat shield for drive axle.
3. Check transmission oil level. See «CHECKING FLUID LEVEL»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level).

BACK-UP LIGHT SWITCH

Note. Back-up light switch is also referred to as a multi-function sender.

Disconnect back-up light harness connector, (multi-function switch), (arrow B). (Scheme 86) Removal and installation procedure not available from manufacturer. Use illustration as an aid for procedure. (Scheme 86)

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

1. 4-cylinder engine: Remove rear section of exhaust system located rearward of exhaust pipe clamp.
2. 6-cylinder engine: Remove Heated Oxygen Sensor (HO2S) from right exhaust pipe using 3337 ring spanner 7-piece set and move clear to side. Remove heat shield above right drive axle. Remove right front exhaust pipe with Three Way Catalytic Converter (TWC) from exhaust manifold (3 nuts, arrows). (Scheme 87)
3. All models: Remove heat shield for driveshaft from Torsen differential cover (arrows). (Scheme 88)
4. Remove driveshaft -1- from transmission and rest it on heat shield -2-. (Scheme 89) Secure driveshaft to fuel line bracket -3- using wire (arrows).
5. Place VAG1306 drip tray underneath and drain transmission oil. Place VAG1306 drip tray underneath end cover.
6. Remove circlip -A-. (Scheme 90) Screw M8 bolt into thread of cap -B-. Pull out cap -B- using bolt. Oil will run out when removing cap -B-.
7. Expand circlip and pull out drive flange. (Scheme 91)
8. Remove drive flange oil seal using VW681 extractor lever. (Scheme 92)

Scheme 88

1. Fill space between sealing lip and dust lip with gear oil. Lightly oil outer circumference of seal.
2. Drive in drive flange seal 2 mm (0.079 in.) below outer housing surface, without canting. (Scheme 93)
3. Install drive flange. While inserting drive flange, install circlip at same time. (Scheme 91) The circlip must be seated in the base of the groove. Replace O-ring for cap. Install cap and secure in position.
4. Install driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS»(/audi/a4/b5-1994-1999/remont/driveshaft-universal-joints/#driveshaft-universal-joints).
5. Top off and check transmission oil level. See «CHECKING FLUID LEVEL»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level).
6. Align exhaust system free of stress.

SHIFT MECHANISM

To identify shifter mechanism components. (Scheme 94)

Scheme 89

Note. Lubricate all mountings and sliding surfaces with Polyurea grease (G 052 142 A2).

Scheme 90

1. Remove shift knob and housing cover. Remove center console.
2. Remove nuts securing shift mechanism housing (arrows). (Scheme 95)
3. Separate exhaust system behind Three Way Catalytic Converter (TWC). If necessary remove front exhaust system together with Three Way Catalytic Converter (TWC). Remove heat shield.
4. Remove driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS»(/audi/a4/b5-1994-1999/remont/driveshaft-universal-joints/#driveshaft-universal-joints).
5. Remove shift rod (arrow -A-). see scheme 31 Remove socket-head bolt on pivot rod (arrow -B-). Swing shift mechanism housing together with shift rod and pivot rod downward and remove.

Note. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Install in reverse order of removal, noting the following: Push shift rod on so that securing bolt fits into recess of shift rod.
2. Secure shift rod (arrow -A-). see scheme 31 Secure pivot rod to transmission (arrow -B-).
3. Adjust shift linkage. See «SHIFT LINKAGE»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a).
4. Install and adjust driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS»(/audi/a4/b5-1994-1999/remont/driveshaft-universal-joints/#driveshaft-universal-joints).
5. Install heat shield. Align exhaust system free of stress.

VEHICLE SPEED SENSOR

Note. This procedure is performed with transmission installed. Vehicle speed sensor is referred to as speedometer sender.

Raise and support vehicle. Disconnect harness connector at Vehicle Speed Sensor (VSS) -A-. see scheme 32 Press retaining clip down, turn sensor sideways and remove upward. Installing: Replace O-ring -B-. Install sensor and lock into place.

Scheme 91

VEHICLE SPEED SENSOR DRIVE WHEEL

Note. Vehicle speed sensor is also referred to as speedometer sender.

Scheme 92

Scheme 93

1. Raise and support vehicle. Remove left drive flange and seal -B-. see scheme 33and «AXLE SEALS»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__axle-seals). Remove Vehicle Speed Sensor (VSS). See «VEHICLE SPEED SENSOR»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__vehicle-speed-sensor).
2. Press retaining clips in direction of arrows using screwdriver. see scheme 34 Remove drive gear by prying out, alternating between sides.

Note. Carefully install drive gear onto differential without canting. Do not use force: the drive gear can break easily.

1. Installation is the reverse order of removal, note the following: Installation position: The drive peg of the drive gear -A- faces seal -B- and locks into groove in the differential. see scheme 33 The retaining clips (arrows) lock in the circumferential groove in the differential. see scheme 33 Always replace seal -B- and circlip -C-. See «AXLE SEALS»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a__axle-seals).
2. Drive in drive flange using VW295 needle bearing drift.
3. Check transmission oil level. Top off to lower edge of fill hole, if necessary. See «LUBRICATION»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a). Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-trans/#servicing-mt-5-speed-01a).

Scheme 94

Scheme 95

Scheme 96

See also:
• DRIVESHAFT & UNIVERSAL JOINTS
• RECOMMENDED FLUID
• SHIFT MECHANISM (FINE ADJUSTMENT)
• REMOVING & INSTALLING (GEAR LOCK FOR FIFTH & REVERSE GEAR)
• BATTERY DISCONNECT PRECAUTIONS
• CHECKING FLUID LEVEL
• AXLE SEALS
• VEHICLE SPEED SENSOR