Clutches - 01a, Awd Audi A4 B6

TRANSAXLE

This article applies to 2002-2004 A4 models with the 1.8L Turbo or 3.0L V6 engine and the 01A all wheel drive manual transaxle.

For locating code letters. (Scheme 160) For locating code letters and date of manufacture. (Scheme 161)

Note. The code letters of the transmission are also engraved on the vehicle data plates.

Scheme 160

Scheme 161

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 162)

Scheme 162

CLUTCH HYDRAULIC SYSTEM

1. Make sure that no brake fluid escapes onto the transmission
2. The clutch system must be bled after carrying out work on the hydraulic clutch mechanism.
3. Top off brake fluid reservoir to "MAX." mark with brake fluid before bleeding clutch system.
4. Use only fresh brake fluid conforming to US standard FMVSS 116 DOT 4. Genuine VW/Audi brake fluid conforms to this specification.

1. Pull clutch pedal back to rest position. Connect brake filler/bleeder unit VAS 5234, but do not switch on. Connect bleeder hose (A) to clutch slave cylinder (arrow) and open bleeder valve. (Scheme 163)
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: 36 psi (2.5 bar). While bleeding, make sure bleeder hose remains correctly routed.
3. Close bleeder valve. Tightening torque: 40 INCH lbs. (4.5 N.m). Depress clutch pedal several times after completion of bleeding process. Bleed system again if necessary.

Scheme 163

CLUTCH PEDAL FREE PLAY

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

CLUTCH PEDAL POSITION SWITCH

Clutch Pedal Position (CPP) Switch (F194), can only be installed one time. No adjustment procedure is given by the manufacturer. For location, see item No. 14 in (Scheme 180).

Shift Mechanism: Adjusting

Note. The following points are essential to ensure correct selector adjustment: Moving parts of selector mechanism and transaxle elements must be in proper condition. Selector mechanism must move freely. Transaxle, clutch and clutch mechanism must also be in proper condition.

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

1. Place transaxle in neutral. Remove the shift lever knob with shift lever cover and cover for center console. Lift off cover for center console upward (arrows). (Scheme 164)
2. Release connector piece (1) in direction of arrow and pull off shift lever knob together with shift lever cover upward. (Scheme 165)
3. Lift off trim (1) first in direction of arrow (A) and then pull out in direction of arrow (B). (Scheme 166)
4. Remove bolts (arrows C) and then pull ashtray (2) from center console. (Scheme 166)
5. Lift up damping washer (1) and noise insulation (2) upward. (Scheme 167)
6. Remove noise insulation from shift lever housing (arrows). (Scheme 168)
7. Measure distance (a) between the two studs in shift mechanism. Measurement is from center of stud to center of stud. (Scheme 169) Specification: Dimension (a) = 85 mm.
8. In case of deviation, adjust distance (a) as follows: Loosen bolt (arrow) for push rod. The rear push rod (in shift mechanism) must move back and forth easily on slide. Adjust measurement (a) by moving rear push rod (in shift mechanism). Tighten bolts for push rod (arrow) to 18 ft. lbs. (25 N.m).
9. Remove bolts for selector rod (arrow). (Scheme 170) The selector rod and shift mechanism connection must move freely.

Scheme 171

1. Center bottom of shift lever centered in ball housing. The distance from ball housing to bottom of shift lever (arrows) must be same at all points. (Scheme 171)
2. Shift lever stands vertical in direction of travel. Hold shift lever in this position. Tighten bolt for selector rod (arrow) to 18 ft. lbs. (25 N.m). (Scheme 170) Install covers and shift lever knob.

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. Gear shift must not come into contact with cover of center console when shifting. Gear shift must automatically return from 5th/reverse gear gate to 3rd/4th gear gate.
3. Reverse gear can only be selected when gear shift is in 3rd/4th gear gate with transmission in neutral beforehand. It is not possible to shift from 5th gear directly to reverse gear.

Note. If gear shift can be shifted directly from 5th gear to reverse, or if only 5th gear and reverse gear cannot be engaged, check locking unit for 5th and reverse gear and replace if necessary.

Scheme 172

1. Remove heat shield (arrow 2) above right drive axle. (Scheme 172) Detach heat shield (arrow 1) above right drive axle and pivot downward. (Scheme 172)
2. Remove gear lock (arrow). (Scheme 173)

Scheme 173

Scheme 174

Scheme 175

1. Insert spring (1) into housing (2) and, while applying light pressure, turn spring to left until it locates in base of housing. (Scheme 174)
2. Insert bushing (3) onto spring so bent end of spring locates into groove properly. (Scheme 174)
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. Lug (arrow A) of bushing must always face away from groove in housing (arrow B). (Scheme 175)
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 175)
8. Installation position of complete gear lock in transmission: The recess (arrow A) faces bolt (arrow B). (Scheme 176)

BATTERY DISCONNECT PRECAUTIONS

After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock. 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. power windows.

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.

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.

OnStar(R) Emergency Battery: Switching Off

1. In order to avoid unnecessary discharge of the emergency (back-up) battery, it must always be switched off prior to disconnecting the vehicle battery, and switched back on after the vehicle battery is reconnected.
2. Use VAS 5051 Vehicle Diagnosis, Testing and Information System in mode: "Guided Fault Finding". Enter appropriate model, equipment and model year information and press right arrow to confirm.
3. After all control modules have been registered and DTC memories checked, press "Go to". Select "Function/Component Selection".
4. Select "01 - On Board Diagnostic (OBD) systems". Select "Telematic". Select "Functions -Telematic".
5. Select "J526 - Telephone/Telematic Ctrl. Module, service mode disc. battery".
6. If necessary, press right arrow to advance. Switch off emergency battery.

OnStar(R) Emergency Battery: Switching On

(Select/press button 3 - "Service mode activating (no load on emergency battery)" - Follow the tester's prompts.

Switch on emergency battery (Select/press button 1). "Service mode deactivating (normal operating condition)". Follow the tester's prompts.

GEAR SHIFT KNOB & COVER

To remove and install gear shift knob and cover (Scheme 177)

Scheme 176

GEAR SHIFT & REAR PUSH ROD

Note. Lubricate bearing and contact surfaces with polycarbamide grease, part no. G 052 142 A2.

To remove and install gear shift and rear push rod (Scheme 178)

Scheme 177

GEAR SHIFT SELECTOR ROD & FRONT PUSH ROD

Note. Carefully pull boot over selector rod. Position boot on markings of selector rod and push rod.

To remove and install gear shift selector rod and front push rod (Scheme 179)

Scheme 178

CLUTCH PEDAL ASSEMBLY OVERVIEW

To identify components (Scheme 180)

Scheme 179

CLUTCH MASTER CYLINDER

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

Special Tools

For special tools for clutch master cylinder work (Scheme 181)and (Scheme 182).

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

1. Remove rubber seal from plenum chamber in direction of arrow. (Scheme 183) Remove cover (1) over plenum chamber.
2. Disconnect battery ground strap with ignition switched off.
3. Use screwdriver to pry off the two caps (3). (Scheme 184) Remove nuts (4) and detach the two wiper arms (2). Pull off clips (1) and remove cowl panel grille (5).
4. Remove electronics box in plenum chamber as follows: Screw out bolts (arrows) and pull off sealing cover. (Scheme 185) Carefully pry off retainer bar with screwdriver (arrow). (Scheme 186) Release connector latches (arrows) and pull off connectors (1) and (2) on engine control module. (Scheme 187) Pull off connector (2) from connector rail. (Scheme 188) Disconnect wire (1). (Scheme 188) Release catches (arrows) and pull auxiliary relay carrier in electronics box upward to remove. (Scheme 189) Pull engine wiring harness together with rubber grommet out of recess in electronics box. Remove nuts (arrows) and lift out electronics box (1). (Scheme 190)
5. Clamp supply hose (A) leading to brake fluid reservoir using special tool 3094. Pull hose off at master cylinder and plug it. (Scheme 191)
6. Disconnect supply hose (A) to brake fluid reservoir with special tool 3094, detach from master cylinder and seal with plug. On bulkhead remove grommet above connecting tube for supply hose. Use a screwdriver to pry out retaining clip (C) and then pull out line (B) slightly. (Scheme 191)
7. Remove bolt from brake fluid reservoir (1) and disconnect connector from fluid level below. (Scheme 192)
8. To remove the top Torx(R) bolt, swivel brake fluid reservoir slightly to one side. Remove the two Torx(R) bolts (arrows). (Scheme 193) Remove vacuum line from brake servo (1).
9. Remove driver's side storage compartment. (Scheme 194)
10. Disconnect brake light switch harness connector. (Scheme 195)
11. Separate brake pedal from brake servo using release tool T40024. (Scheme 196)
12. Disconnect steering column from steering gear (arrow A). (Scheme 197)
13. Disconnect connector on clutch pedal switch (1), brake pedal switch (2) and on accelerator pedal module (3). (Scheme 197)
14. Remove securing bolt from mounting bracket (arrow B) and complete pedal cluster. (Scheme 197)
15. Removing over-center spring. See «CLUTCH PEDAL & OVERCENTER SPRING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-pedal-overcenter-spring).
16. Insert pliers VAG 1922 into recess of clutch pedal, press retainer together (arrows) and detach clutch pedal from master cylinder. (Scheme 198)
17. Remove retaining clip (1) and pull off clutch pedal (2). (Scheme 199) Remove bolts (3) and detach master cylinder (4).
18. Pull off retainer (A) in direction of arrow. (Scheme 200)

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. Press master cylinder operating rod into retainer (A) in direction of arrow. (Scheme 201)
2. Insert master cylinder and tighten screws (3) to 15 ft. lbs. (20 N.). (Scheme 199)
3. Insert retainer into clutch pedal. See No. 10 in (Scheme 180). Press clutch pedal to engage master cylinder retainer. Make sure that retainer is correctly locked in clutch pedal.
4. Install over-center spring. See «CLUTCH PEDAL & OVERCENTER SPRING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-pedal-overcenter-spring).
5. A second mechanic is required for this step. Insert complete pedal cluster and install bolt (1) hand-tight. (Scheme 202) The second mechanic must simultaneously insert line into master cylinder from plenum chamber side.
6. Tighten bolts for brake servo (arrows) to 18 ft. lbs. (25 N.m). (Scheme 203)
7. Press in retaining clip (C) up to stop. (Scheme 204) Insert line (B) into master cylinder until it is heard to engage. (Scheme 204) Insert rubber grommet (D) over supply hose connecting line (A) into bulkhead.
8. Slide supply hose (A) for the brake fluid reservoir up to stop. (Scheme 204) Remove special tool 3094. Install bolt for brake fluid reservoir.
9. Tighten hex socket-head bolt for securing pedal cluster on instrument panel support to 18 ft. lbs. (25 N.m).
10. Plug in harness connectors. Connect brake pedal to brake servo.
11. Secure steering column to steering gear. Tighten bolt to 22 ft. lbs. (30 N.m).
12. Install driver's storage compartment.
13. Bleed clutch system. See «CLUTCH HYDRAULIC SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-hydraulic-system) under BLEEDING.
14. Insert electronics box and tighten nuts (arrows) to 35 INCH lbs. (4 Nm). (Scheme 205) Route engine wiring harness and connect connectors to connector point. Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.
15. Press on sealing cover hand-tight and tighten screws in diagonal sequence to 35 INCH lbs. (4 Nm). On re-connecting battery, remember to check and re-activate vehicle equipment (radio, clock, convenience electronics, etc.).

Scheme 202

1. Use a screwdriver to remove hose and line assembly, pull out clip (A) up to stop. (Scheme 206)
2. Separate slave cylinder from hose and pipe assembly. Pull out hose and pipe assembly. (Scheme 206).

Scheme 203

1. Push in clip (A) as far as it will go. (Scheme 206) Insert hose/pipe assembly in slave cylinder until it clicks into position. Check proper installation by pulling hose/pipe assembly.
2. Apply a thin layer of copper paste (e.g. Z 381 351 TE) to contact surface for plunger on clutch release lever. (Scheme 207) Before installing slave cylinder in transmission housing lubricate area (a) of boot with lithium base grease G 052 150 A2.
3. Lock bracket for hose/pipe assembly (3) on slave cylinder (4) and bolt onto transmission together with slave cylinder. (Scheme 208) Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from direction of motion of plunger. (Scheme 208)
4. Bleed clutch system. See «CLUTCH HYDRAULIC SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-hydraulic-system) under BLEEDING.

CLUTCH PEDAL & OVERCENTER SPRING

To remove overcenter spring, special tool Installation Clamp T40025 is required. (Scheme 209)

Scheme 204

Scheme 205

Scheme 206

1. Remove driver's side storage compartment. (Scheme 210) If installed, remove switch above clutch pedal.
2. Tension overcenter spring with clutch pedal and press on installation clamp T40025. (Scheme 211)
3. Bring clutch pedal to rest position and take out overcenter with spring and installation clamp T40025 from below.

Installation

1. Installation is the reverse of removal, note the following points.
2. Pull clutch pedal into passenger compartment. Installation position overcenter spring: Black end overcenter spring points toward clutch pedal.
3. Insert overcenter spring with installation clamp T40025, depress clutch pedal and pull out installation clamp.

CLUTCH RELEASE MECHANISM OVERVIEW

To identify clutch release mechanism components (Scheme 212)

Scheme 207

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 215)

Removal

1. Turn ignition switch to OFF position. Disconnect negative battery cable. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__battery-disconnect-precautions) .
2. Remove transaxle. See «TRANSAXLE (ALL WHEEL DRIVE)»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__transaxle-all-wheel-drive) . 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 208

1. Inspect pressure plate surface for wear, cracks, burning or warpage. Inspect pressure plate diaphragm spring for wear. (Scheme 213) Up to half thickness of diaphragm spring is permitted.
2. Check clutch release bearing for wear and replace if necessary. If plastic ring of release bearing is loose, stick back onto bearing ring with adhesive AMV 195 KD1 01. Three rectangular lugs (arrows) on plastic ring engage in recesses in bearing ring. (Scheme 250) If scores deeper than 0.5 mm are present, replace release bearing. 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 214)
4. Inspect flywheel ring gear teeth for wear and damage. Inspect flywheel for wear, cracks and burned condition. If flywheel needs service or replacement or if pilot bearing needs replacing, see «DUAL-MASS FLYWHEEL & PILOT NEEDLE BEARING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd).

Scheme 209

Scheme 210

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: Damping set (coil springs) or writing "Getriebeseite" must face pressure plate or transmission. Only install attachment bolts once contact surface of pressure plate and lining of clutch plate are located completely on flywheel. Use centering mandrel 3176 to center clutch plate.
3. If White spots exist on flywheel and pressure plate (A and B), align them during assembly. (Scheme 215)
4. Install pressure plate bolts finger tight. Using clutch centering tool (3176), align clutch disc and pilot bushing holes. (Scheme 216) Tighten pressure plate bolts to specification using a crosswise pattern. Install transaxle. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__torque-specifications).

Scheme 211

1. Dual-mass flywheel pilot needle bearing, removing and installing: Remove pilot needle bearing using puller (A) (e.g. KUKKO 21/2 and KUKKO 22/1). (Scheme 217) Install pilot needle bearing using 3264 bearing driver.
2. Install 10-201 flywheel retainer to loosen and tighten bolts. (Scheme 218) 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/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__torque-specifications).

Removal & Installation (1.8L Turbo): Conventional Flywheel & Pilot Needle Bearing (Pilot Needle Bearing Installed In Crankshaft)

Special tools: Special tool drift VW 207 C. (Scheme 219) Special tools expander Kukko 21/1 (1) and puller Kukko 22/1 (4). (Scheme 219) A depth gauge is also needed (not shown).

Scheme 212

Note. A pilot needle bearing must be installed in crankshaft on vehicles with manual transmission. Install pilot needle bearing if necessary.

Scheme 213

Scheme 214

1. Pull out pilot needle bearing using Kukko 21/1 and Kukko 22/1. (Scheme 220)
2. Drive in with drift 207c or centering mandrel 3176. (Scheme 221) Lettering on pilot needle bearing must be visible when installed.
3. Installation depth for pilot needle bearing: Distance a =.059" (1.5 mm). (Scheme 222)

Removal & Installation (3.0L): Dual-Mass Flywheel & Pilot Needle Bearing

Scheme 215

Scheme 216

Scheme 217

Scheme 218

1. Turn crankshaft via center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking. Notch (1) lines up with marking (2). (Scheme 223)
2. If installed, disconnect electrical harness connector at after-run coolant pump.
3. Unscrew sealing plug of TDC mark at cylinder block. (Scheme 223) Thread T40026 locking pin into the hole of the removed sealing plug and tighten, (slightly turn crankshaft back and forth to do so). (Scheme 224)and (Scheme 225).
4. Remove clutch pressure plate. See «REMOVAL»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd). Mark location flywheel to engine for re-installation.
5. Installation is reverse of removal, noting the following: Install flywheel. Tighten flywheel bolts, using a cross pattern. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__torque-specifications).
6. Install clutch pressure plate. See «INSTALLATION»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd). Remove T40026 alignment locking pin and thread sealing plug of TDC marking with new O-ring into cylinder block.
7. If pilot bearing needs to be replaced, pull out needle bearing using Kukko 21/1 and Kukko 22/1. (Scheme 226) Drive needle bearing into flywheel using 3264 bearing driver.
8. Needle bearing installation depth (2): To measure the installation depth, place a metal ruler onto plastic ring (1) of dual-mass flywheel. Measurement x = 0.5 mm. (Scheme 227)

TRANSAXLE (ALL WHEEL DRIVE)

Note. OnStar(R) Emergency Battery (Audi Telematics) turning off/on procedure is included in BATTERY DISCONNECT PRECAUTIONS .

Scheme 219

Scheme 220

Removing: 1.8L Turbo & 3.0L V6 (All Wheel Drive)

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

1. Obtain radio code on vehicles with coded radio. Disconnect battery ground strap with the ignition switched off. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__battery-disconnect-precautions).
2. Remove engine cover (arrows). (Scheme 230)
3. Fit support bar 10-222 A with supports 10-222 A/1. (Scheme 231) Tighten engine slightly using the spindles.
4. Detach noise insulation (arrows). (Scheme 232)
5. Remove bracket for noise insulation (arrow). (Scheme 233)
6. Unscrew heat shield for drive shaft from Torsen differential housing (arrows). (Scheme 234)
7. Release clamp (1) and remove front part of exhaust pipe (2). (Scheme 235) Place mating marks on driveshaft and transmission flanges for reassembly reference. Unscrew drive shaft (3) from transmission and secure at side with wire.
8. Re-insert speed nut (arrow) slightly and secure drive shaft with wire. (Scheme 236)
9. Remove heat shield (arrows 1 and 2) above right drive axle shaft. (Scheme 237) If installed, remove left drive axle heat shield.
10. Remove the three lower engine and transmission connecting bolts (arrow). (Scheme 238)
11. Remove the drive axle shafts (1) from the flange shafts and tie these up. (Scheme 239)
12. Support transmission with engine and transmission lifter VAG 1383 A. Remove bolts (2) and then bolts (3) on tunnel cross member. (Scheme 239) Remove the two nuts (4) and detach tunnel cross member (2).
13. Lower engine and transmission lifter VAG 1383 A and place to one side.
14. Remove selector rod (arrow A). Remove hex socket-head bolt on push rod (arrow B). (Scheme 240)
15. Disconnect connector off speedometer sensor (arrow A). Disconnect connector on reversing light switch (multi-function sensor), (arrow B). (Scheme 241) Disconnect all other electrical connections and ground wires from transmission and from the engine and transmission securing bolts.
16. If installed, remove engine speed (RPM) sensor (G28) on left of transmission (arrow) and lay to one side. (Scheme 242)
17. Remove starter from engine and transmission and secure. It is not necessary to disconnect starter cables. (Scheme 243)
18. Remove lower engine and transmission connecting bolts, except for bolts (arrow A) and (arrow B). (Scheme 244)
19. Set the transmission support 3282 for removing the manual 01A with adjustment plate 3282/10 and attach to transmission lifter VAG 1383 A. (Scheme 245)
20. Place transmission lifter under vehicle. Arrow (B) on adjustment plate points in direction of travel. (Scheme 246)
21. Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission. (Scheme 247)
22. Remove engine and transmission connecting bolts (arrows A and B). (Scheme 244)
23. Push transmission off dowel sleeves and lower carefully with transmission lifter VAG 1383 A just far enough to access the slave cylinder. (Scheme 248) Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect lines.
24. Lower transmission. Secure transmission to repair stand with transmission support VW 353 and retaining plate VW 309 to carry out repairs. See «SECURING & TRANSPORTING TRANSAXLE: ALL WHEEL DRIVE»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd).
25. If the transmission is exchanged, the transmission mount must be transferred to the exchange transmission. (Scheme 249)

Scheme 238

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 release 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. If plastic ring on release bearing is detached, adhere this back onto bearing ring with adhesive AMV 195 KD1 01. Three right-angled lugs (arrows) on plastic ring engage in the recesses on bearing ring. (Scheme 250) If ridges are deeper than 0.5 mm, replaced release bearing.
4. 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.
5. Check whether dowel sleeves for aligning engine/transaxle are installed correctly in cylinder block, install or replace if necessary.
6. Always replace self-locking nuts.
7. Ensure intermediate plate (if installed) is correctly positioned on engine.

Scheme 239

1. Lift transaxle until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow). (Scheme 248)
2. Install lower engine/transaxle and starter mounting bolts and install starter.
3. Install tunnel cross member onto transmission mount (4). (Scheme 239) Install tunnel cross member onto body. First install bolts (3) and then bolts (2), firmly screw tunnel crossmember to body. (Scheme 239)
4. Replace gaskets on drive shaft flange shafts (detach protective foil and stick gasket onto flange shaft). To prevent driveshaft imbalance, align mating marks made during removal and attach drive shaft to transmission using NEW self-locking bolts. Tighten to 41 ft. lbs. (55 N.m).
5. Align exhaust system free of stress. See «ALIGNING EXHAUST SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__aligning-exhaust-system).
6. 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. (Scheme 251)
7. To check oil level, remove oil filler plug (arrow). (Scheme 252) Check oil level with hand-made tool (e.g. bent wire). Oil level should be 0.276 in. (7 mm) below bottom of filler hole. Use gear oil SAE 75 W 90 (synthetic oil), part number G 005 000 (1 liter) to top off transmission oil if necessary. Install oil filler plug. Tightening torque: 18 ft. lbs. (25 N.m).
8. Check adjustment of shift mechanism and adjust if necessary. See «SHIFT MECHANISM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd).
9. Ensure all fasteners are tightened to specifications. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__torque-specifications).
10. Connect battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__battery-disconnect-precautions). 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 assembly stand using VW353 transmission support and VW309 holding plate when working on transaxle. (Scheme 253)

Scheme 240

Transporting Transaxle: All Wheel Drive

Lifting tackle 2024 A in conjunction with auxiliary hook 10-222 A can be used for transporting the transmission. (Scheme 254)

Scheme 241

1. Screw on two brackets of lifting tackle 2024 A using bolts (A) M10 x 50. (Scheme 254)
2. Attach lifting tackle 2024 A and raise slightly with workshop crane. (Scheme 254)
3. Hook 4th hole of each hole rail into position (3) and position (6) of lifting tackle 2024 A. (Scheme 254)

Aligning Exhaust System

Align exhaust so components are free of stress. See ALIGNING EXHAUST SYSTEM: A4 1.8L TURBO (ENGINE CODE AMB) or ALIGNING EXHAUST SYSTEM: A4 3.0L V6 (ENGINE CODE AVK) .

Aligning Exhaust System: 1.8L Turbo (Engine Code AMB)

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.

Scheme 242

Scheme 243

Scheme 244

Scheme 245

1. Align exhaust system when cold. Double clamp is located at the front of front muffler pipe. Loosen double clamp bolts. (Scheme 255) Push exhaust system forward (arrow) until tension on rear mount equals dimension a in see scheme 97. Dimension a is 0.197-0.354 in. (5-9 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 98 Tighten evenly to 30 ft. lbs. (40 N.m).
3. Align tailpipes. Check distance (a) between tailpipe (1) and bumper (2). Distance (a) = at least 40 mm. see scheme 99

Scheme 246

Scheme 247

1. Align exhaust system when cold. Double clamp is located at the front of front muffler pipe. Loosen double clamp bolts. (Scheme 255)
2. Push exhaust system forward (arrow) until tension on rear mount equals dimension a in see scheme 100. Dimension a is 0.197-0.354 in. (5-9 mm).
3. 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 98 Tighten evenly to 30 ft. lbs. (40 N.m).
4. Push rear section of exhaust system toward front of vehicle (arrow) until preloading at rear mounting of rear muffler is a = 12 mm.
5. Make sure that center muffler is horizontal to bottom of vehicle (as viewed at right angle to direction of travel).
6. Tighten bolted connections on rear clamp evenly to 30 ft. lbs. (40 Nm). see scheme 101
7. Align tailpipes. Check distance (a) between tailpipe (1) and bumper (2). Distance (a) = at least 40 mm. see scheme 99

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.

Scheme 248

Scheme 249

Scheme 250

1. Remove bolts (1) through (4) and remove crossmember. see scheme 102 Loosen double clamp bolts at front pipes.
2. Push exhaust system far enough forward (arrow) so that the pre-tension at the right retaining loop at center muffler (a) = 5 to 9 mm. see scheme 97 Tighten double clamp bolts uniformly to 30 ft. lbs. (40 N.m).
3. Align tailpipes. Check distance of tailpipes at left and right to bumper: Dimension (x) left and dimension x right should be the same. see scheme 103
4. If necessary, correct dimension (x) as follows: Loosen nuts (arrows) of brace between exhaust pipes. see scheme 104 Change the distance of the rear mufflers to each other. Tighten nut to 17 ft. lbs. (23 N.m).
5. Check distances (y) and (z) of tailpipes to bumper. see scheme 105 Dimension (y) should be greater than 20 mm. Dimension (z) should be 9 to 14 mm. see scheme 105 Check whether the exhaust system is installed free of stress.
6. Install crossmember. Tighten to 41 ft. lbs. (55 N.m). see scheme 102

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.

CLUTCH SLAVE CYLINDER

Information not available from manufacturer.

TORQUE SPECIFICATIONS

Note. For engine-to-transmission bolts: Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened. Other lubricants are permitted (e.g. engine oil or transmission fluid); however, they may not contain graphite. Do not use any degreased parts.

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

See also:
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• BATTERY DISCONNECT PRECAUTIONS
• CLUTCH PEDAL & OVERCENTER SPRING
• CLUTCH HYDRAULIC SYSTEM
• TRANSAXLE (ALL WHEEL DRIVE)
• TORQUE SPECIFICATIONS
• ALIGNING EXHAUST SYSTEM
• ALIGNING EXHAUST SYSTEM: A4 1.8L TURBO (ENGINE CODE AMB)