Clutches - 01e, Awd Audi A4 B6

TRANSAXLE

The manual transmission 01E AWD is installed in the Audi A4 as an optional equipment 6-speed transmission in conjunction with the 3.0L V6 engine.

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. The transaxle code letters are also included on the vehicle data stickers.

For identification locations on transaxle, see list below.

1. Code letters and consecutive serial numbers (arrow 1). (Scheme 79)
2. Manual transmission 01E (arrow 2). (Scheme 80)

Scheme 79

Scheme 80

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 81)

Scheme 81

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.

1. While bleeding, make sure bleeder hose remains correctly routed. 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 82)
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 82

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 90).

Adjusting

The following are prerequisites for correct gear linkage adjustment.

1. Perfect gear linkage operating and transfer elements.
2. Gear shift lever mechanism moves smoothly.
3. Transmission, clutch and clutch mechanism must be in proper condition.
4. Transmission in neutral.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

1. Remove shift knob with cover: Unclip cover for center console and lift this out upward -arrows-. (Scheme 83)
2. Detach connecting part -1- in direction of arrow and pull off shift knob together with shift lever cover upward. (Scheme 84)
3. Vehicles with small radio compartment: Lift panel -1- first in direction of arrow -A- and pull out in direction of arrow -B-. (Scheme 85) Vehicles with large radio compartment. Remove A/C control head.
4. Unscrew the bolts -arrows C- and pull out the ashtray -2- from the center console. (Scheme 85) Disconnect electrical harness connector for ashtray lighting. Remove foam wedges from center console. Lift out the upper noise insulation upward.
5. Unscrew lower noise insulation cover for shift lever housing -arrows-. (Scheme 86)
6. Measure distance -a- between the two threaded studs in the shift lever mechanism. (Scheme 87) Specified value: Distance a =.335" (85) mm.
7. If this is not the case, adjust distance -a- as follows: Loosen push rod bolt (arrow). (Scheme 87) Rear push rod (in shift lever mechanism) should move freely in both directions on slide. Set distance -a- by moving rear push rod (in shift lever mechanism). Tighten push rod bolt -arrow- to 23 Nm.

Scheme 88

1. Align the shift lever as follows: Loosen bolt for selector rod -arrow-. (Scheme 88) Connection between selector rod and shift lever mechanism should move freely.
2. Center the bottom of the gear lever in the center of the ball housing. The distance between the ball housing and the bottom of the gear lever -arrows- must be equal at all points. (Scheme 89)
3. Shift lever in vertical position to direction of travel. Shift lever held in this position. Tighten selector rod bolt -arrow- to 23 Nm. (Scheme 88)

Shift Lever Alignment (Checking)

1. The shift lever must rest in the 3rd/4th gear gate when the transmission is in neutral.
2. Depress clutch. Check that all gears can be engaged. Check operation of reverse gear lock. It should only be possible to engage the R gear after releasing the block.
3. The gear lever must return automatically from the R gear gate to the 3rd/4th gear gate.
4. If after repeated selection of a gear it fails to engage smoothly, shift lever alignment must be repeated.
5. Install covers and shift lever knob.

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. After battery has been disconnected, readiness code for Electronic Control Module (ECM) must be re-generated. 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 ">" 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 ">" 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.

CLUTCH PEDAL ASSEMBLY & CLUTCH CONTROL OVERVIEW

To identify components (Scheme 90)

Scheme 89

CLUTCH MASTER CYLINDER

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

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

1. Remove rubber seal from plenum chamber in direction of arrow. (Scheme 93) 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 94) 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 95) Carefully pry off retainer bar with screwdriver (arrow). (Scheme 96) Release connector latches (arrows) and pull off connectors (1) and (2) on engine control module. (Scheme 97) Pull off connector (2) from connector rail. (Scheme 98) Disconnect wire (1). (Scheme 98) Release catches (arrows) and pull auxiliary relay carrier in electronics box upward to remove. (Scheme 99) Pull engine wiring harness together with rubber grommet out of recess in electronics box. Remove nuts (arrows) and lift out electronics box (1). (Scheme 100)
5. Clamp supply hose (A) leading to brake fluid reservoir using special tool 3094. Pull hose off at master cylinder and plug it. (Scheme 101)
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 101)
7. Remove bolt from brake fluid reservoir (1) and disconnect connector from fluid level below. (Scheme 102)
8. For ease of illustration, brake fluid reservoir is not shown. To remove the top Torx(R) bolt, swivel brake fluid reservoir slightly to one side. Remove the two Torx(R) bolts (arrows). (Scheme 103) Remove vacuum line from brake servo (1).
9. Remove driver's side storage compartment. (Scheme 104)
10. Disconnect brake light switch harness connector. (Scheme 105)
11. Separate brake pedal from brake servo using release tool T40024. (Scheme 106)
12. Disconnect steering column from steering gear (arrow A). (Scheme 107)
13. Disconnect connector on clutch pedal switch (1), brake pedal switch (2) and on accelerator pedal module (3). (Scheme 107) Remove securing bolt from mounting bracket (arrow B) and complete pedal cluster.
14. Removing over-center spring. See «CLUTCH PEDAL & OVERCENTER SPRING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__clutch-pedal-overcenter-spring).
15. Insert pliers VAG 1922 into recess of clutch pedal, press retainer together (arrows) and detach clutch pedal from master cylinder. (Scheme 108)
16. Remove retaining clip (1) and pull off clutch pedal (2). (Scheme 109) Remove bolts (3) and detach master cylinder (4). (Scheme 109)
17. Pull off retainer (A) in direction of arrow. (Scheme 110)

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Press master cylinder operating rod into retainer (A) in direction of arrow. (Scheme 111)
2. Insert master cylinder and tighten screws (3) to 15 ft. lbs. (20 N.m). (Scheme 109)
3. Insert retainer into clutch pedal. See No. 10 in (Scheme 90) (Scheme 90). Press clutch pedal to engage master cylinder retainer. See. 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-01e-awd__clutch-pedal-overcenter-spring).
5. A second mechanic is required for this next step. Insert complete pedal cluster and install bolt (1) hand-tight. (Scheme 112) 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 113)
7. Press in retaining clip (C) up to stop. (Scheme 114) Insert line (B) into master cylinder until it is heard to engage. (Scheme 114) Insert rubber grommet (D) over supply hose connecting line (A) into bulkhead. (Scheme 114)
8. Slide supply hose (A) for the brake fluid reservoir up to stop. (Scheme 114) 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-01e-awd__clutch-hydraulic-system) under BLEEDING.
14. Insert electronics box and tighten nuts (arrows) to 35 INCH lbs. (4 Nm). (Scheme 115) 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.).

CLUTCH SLAVE CYLINDER

Note. Do not depress clutch pedal after removing slave cylinder.

Removing Without Separating From Hydraulic Lines

Remove bolt -arrow-, remove clutch slave cylinder rearward. see scheme 91

Scheme 113

1. Use a screwdriver to remove hose and line assembly, pull out clip (A) up to stop. (Scheme 116)
2. Separate slave cylinder from hose and pipe assembly. Pull out hose and pipe assembly. (Scheme 116).

Scheme 114

1. Push in clip (A) as far as it will go. (Scheme 116) 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 117) Before installing slave cylinder in transmission housing lubricate area (a) of boot with lithium base grease G 052 150 A2. (Scheme 117)
3. Lock bracket for hose/pipe assembly (3) on slave cylinder (4) and bolt onto transmission together with slave cylinder. (Scheme 118) Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from direction of motion of plunger.
4. Bleed clutch system. See «CLUTCH HYDRAULIC SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__clutch-hydraulic-system) under BLEEDING.

CLUTCH PEDAL & OVERCENTER SPRING

To remove overcenter spring, special tool Installation Clamp T40025 is required. (Scheme 119)

Scheme 115

To identify components (Scheme 120)

Scheme 116

Scheme 117

Scheme 118

1. Remove driver's side storage compartment. (Scheme 121) If installed, remove switch above clutch pedal.
2. Tension overcenter spring with clutch pedal and press on installation clamp T40025. (Scheme 122)
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. (Scheme 122)

CLUTCH RELEASE MECHANISM OVERVIEW

To identify clutch release mechanism components (Scheme 123)

Scheme 119

CLUTCH ASSEMBLY

To identify clutch assembly components. (Scheme 124)

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Removal

Note. On models with theft protection system, obtain radio security code from vehicle owner before disconnecting battery cable. Switch the ignition off (also applies when connecting the battery), failure to do so may damage the Engine Control Module (ECM). See BATTERY DISCONNECT PRECAUTIONS .

Note. For vehicles with the optional 01E 6 Speed Transaxle and 3.0L V6 engine, a (SAC clutch plate (self adjusting clutch plate) is installed, on which an adjustment ring must be reset except during replacement.

Note. If the clutch has burned out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission to reduce the smell of burned linings.

Scheme 124

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-01e-awd__battery-disconnect-precautions). Remove transaxle. See «TRANSAXLE»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd).
2. Install flywheel lock 10201 in the position for loosening bolts. (Scheme 128)
3. Loosen pressure plate bolts gradually, in a crosswise pattern. Remove pressure plate and clutch disc.

Inspection

Note. Replace clutch plates and pressure plates with damaged or loose rivets. Select the correct clutch plate and pressure plate according to engine code.

Scheme 125

1. Check ends of diaphragm springs, wear up to half of the diaphragm spring thickness is permissible. (Scheme 129) Check diaphragm springs and spring connection between pressure plate and cover for cracks, rivet connections and for secure fit. Replace clutches with damaged springs or with loose rivet connections (arrows). (Scheme 129)
2. Check dual-mass flywheel. Ensure centering pins are tightly seated. Contact surface for clutch lining must be free of grooves, oil and grease. If dual-mass flywheel needs servicing. See «DUAL-MASS FLYWHEEL & PILOT NEEDLE BEARING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__dual-mass-flywheel-pilot-needle-bearing).

Note. To avoid damaging centering holes in pressure plate and centering pins on flywheel, tighten securing bolts evenly and in several stages in diagonal sequence.

1. Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Excess grease must be removed. Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.
2. When fitting a new clutch plate together with a used SAC pressure plate, the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. See «ADJUSTING SAC PRESSURE PLATE»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__adjusting-sac-pressure-plate). Surface of pressure plate to clutch disc and clutch disc to flywheel all must make full contact before securing bolts are inserted.
3. If the clutch disc is being replaced and the pressure plate is not being replaced, the pressure plate has to be reset. See «ADJUSTING SAC PRESSURE PLATE»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__adjusting-sac-pressure-plate). In all other clutch disc/pressure plate, new/used combinations, go to next step.
4. Position of clutch disc: spring pack (coil springs) or marking "Getriebeseite" towards pressure plate and transmission. Tighten bolts gradually in diagonal sequence and in several stages to 16.5 ft lbs (22 Nm). Reverse position of counter-hold tool 10-201 when removing. Use mandrel 3176 to center clutch plate. (Scheme 128)

Adjusting SAC Pressure Plate

SAC stands for Self-Adjusting-Clutch. When fitting a new clutch disc together with a used SAC pressure plate, the adjuster ring in the SAC pressure plate has to be reset by turning it back as far as it will go. If this is not done, the SAC pressure plate will operate with reduced clamping force, which will cause clutch slip and excessive wear (especially of the clutch disc). This adjustment is only required when fitting a new clutch disc together with a used SAC pressure plate.

If the clutch disc is not being replaced, it is not necessary to reset the adjuster ring. New SAC pressure plates are pre-set accordingly, and do not have to be reset.

Scheme 126

Scheme 127

1. Insert 3 securing bolts -A- into mounting holes on pressure plate, 120° from each other (1/3 turn), as shown in illustration. (Scheme 130) Thread 3 nuts -B- (M8) onto bolts -A- and tighten nuts slightly. (Scheme 130)
2. Place SAC pressure plate onto press so that only the 3 bolt heads (arrows) make contact. (Scheme 131) Position special tool 3062 in center of pressure plate.
3. Apply two screwdrivers to forks on adjuster ring. (Scheme 132) Use press to compress pressure plate until it is just possible to move adjuster ring. (Scheme 132)
4. Using two screwdrivers, turn back adjuster ring evenly in direction of arrows until it reaches stop. (Scheme 132)
5. Hold adjuster ring against stop and reduce pressure exerted by press so that adjuster ring is held in this position. (Scheme 132).

DUAL-MASS FLYWHEEL & PILOT NEEDLE BEARING

Scheme 128

Scheme 129

Scheme 130

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 133)
2. If installed, disconnect electrical harness connector at after-run coolant pump.
3. Unscrew sealing plug of TDC mark at cylinder block. (Scheme 133) Thread T40026 locking pin into the hole of the removed sealing plug and tighten, (slightly turn crankshaft back and forth to do so). (Scheme 134)and (Scheme 135).
4. Remove clutch pressure plate. See «REMOVAL»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-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-01e-awd).
6. Install clutch pressure plate. See «INSTALLATION»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-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 137) 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 =.020" (0.5 mm). (Scheme 136)

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Before disconnecting the battery: Determine the correct coding for the anti-theft radio. Switch the ignition off (also applies when connecting the battery), failure to do so may damage the Engine Control Module (ECM). On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__battery-disconnect-precautions).
2. Slide cover over the battery to the right (arrow 1) and pull it off upward (arrow 2). (Scheme 139)
3. Disconnect battery Ground (GND) strap (arrow) with the ignition switched off. (Scheme 140)
4. Remove rear engine cover (arrows). (Scheme 141)
5. Remove front engine cover (arrows). (Scheme 142)
6. Remove cover -1- in engine compartment (right side). (Scheme 143)
7. Remove bolts for holding plate -3- for solenoid valves (arrows). (Scheme 144) Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor. Remove hose -4- of crankshaft housing ventilation from air duct -2-. (Scheme 144)
8. Remove engine/transmission connecting bolts accessible from above.
9. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module. (Scheme 145) Disconnect hose -1- from air duct.
10. Position 10-222A engine support bridge on bolted flanges of fenders. (Scheme 146)
11. Remove eyelet for 2024A engine sling. Insert bolt -1- in the center bore of 2024A Engine Sling and secure with a cotter pin. (Scheme 147) Attach bolt for 2024A engine sling at 10-222A engine support bridge spindle. Attach 2024A Engine Sling to sling clamps at front and rear of engine. Slightly pre-tension engine using engine support bridge spindle.
12. Remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation. (Scheme 148)
13. Remove the sound-proofing material (arrows). (Scheme 149)
14. Unbolt bracket for noise insulation panel (arrow). (Scheme 150)
15. Disconnect exhaust system at double clamps -arrows-. (Scheme 151) Detach rear part of exhaust system on retaining loops and remove it.
16. Remove heat shield for drive axle -arrows-. (Scheme 152)
17. Place mating marks on driveshaft and transaxle flanges for reassembly reference, and remove bolts at flange of transmission/drive axle. Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially. Secure driveshaft -1- with wire (arrow) to heat shield. (Scheme 153)
18. Remove VAG1359/2 universal mount from VAG1383A engine/transmission jack and place a piece of wood -arrow- onto punch instead. (Scheme 154) Support tunnel cross member using VAG1383A engine/transmission lift. First remove bolts -1- and -2-, then bolts -3- and -4-. Release slowly the tunnel cross member using VAG1383A engine/transmission lift.
19. Remove nuts -1- and -2-. (Scheme 155) Remove bolts (arrows) and remove tunnel cross member downward using transmission mount.
20. Remove left and right heat shields for drive axles (arrows). (Scheme 156) Remove drive axles from transmission drive flange.
21. Raise transmission using punch of VAG 1383 A engine/transmission hoist high enough, so that a piece of wood (arrow) can be placed in between. (Scheme 157)
22. Remove the three bottom engine/transmission connecting bolts (arrows). (Scheme 158) Lower transmission again.
23. Unbolt starter -1- (arrows) and remove it from transmission bell housing. (Scheme 159) Remove remaining mounting bolts for engine/transmission. One bolt remains tightened by hand.
24. Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire. see scheme 82
25. Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission. see scheme 83
26. Unbolt heat shield for engine speed (RPM) sensor. Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side. see scheme 84
27. Disconnect connecting rod -2- of shift rod. see scheme 85 Remove pivot rod -1-, to do this unbolt socket-head bolts.
28. Remove nut -1- and pull transaxle shift lever -2- from shift rod of transaxle. see scheme 86
29. Set up 3282 transmission support for removing manual transmission 01E all wheel drive using 3282/12 adjustment plate and VAG1383A engine/transmission hoist. see scheme 87
30. Roll VAG 1383 A engine/transmission hoist underneath transaxle. see scheme 89 Arrow B on adjustment plate 3282/12 points in the direction of travel. see scheme 88
31. Align adjustment plate parallel to transmission and lock safety support (arrow) on transaxle. see scheme 90 Remove last mounting bolts for engine/transmission. Press transmission off dowel sleeves and lower carefully using VAG 1383 A engine/transmission hoist just enough for access to slave cylinder. see scheme 90
32. Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect line. see scheme 91 Lower transmission completely.

Installation is carried out in the reverse order.

Scheme 154

1. Always replace all seals and gaskets.
2. Always replace all self-locking nuts.
3. Check whether dowel sleeves for aligning transmission with engine are in engine flange. Replace or insert if necessary.
4. Clean input shaft splines and (in the case of used clutch plates) hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to splines. Do not grease guide sleeve.
5. Check clutch release bearing for wear and replace if necessary.
6. If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-195-KD1-01.
7. 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the release bearing ring. see scheme 92 If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
8. All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid using a tap.
9. Place intermediate plate onto the dowel sleeves on engine flange.
10. Tie electrical wires off to the side before installing, so that they are not pinched between engine and transmission.

Scheme 155

Scheme 156

1. Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow). see scheme 91. Secure slave cylinder with a new bolt (arrow). Install starter and secure connecting bolts for engine/transmission on left and right side. Install connecting rods and pivot rods for shift mechanism.
2. Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise transmission slightly. (Scheme 157)
3. Tighten the three bottom engine/transmission connecting bolts (arrows). (Scheme 158) Lower transmission again.
4. Guide the tunnel cross member with loosely inserted transmission mount over front exhaust pipes.
5. Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise tunnel cross member and transmission slightly. see scheme 93 Next, tighten bolts -1- to -4- hand-tight. see scheme 93 Release slowly the VAG 1383 A engine/transmission hoist. Tighten bolts for tunnel cross member.
6. For tension-free installation, raise transmission using punch of VAG 1383 A engine/transmission hoist high enough so that a piece of wood -1- can be placed in between. see scheme 94 Tighten bolts (arrows) for transaxle mount. Slowly lower transmission again. Tighten nuts -2- and -3-.
7. Install bolt drive axles on drive flange using NEW self-locking bolts.
8. Aligning mating marks made during removal, secure driveshaft to transmission. Use NEW self-locking bolts. See «DRIVESHAFT & UNIVERSAL JOINTS»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle) article for more information.
9. Check adjustment of shift mechanism and adjust if necessary. See «SHIFT LEVER MECHANISM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd).
10. Install and adjust exhaust system free of stress.
11. Check oil level in transaxle. Remove oil filler plug (B), (in front of drive flange) to check transmission oil level. see scheme 95 Check oil level with a suitable tool (such as a length of wire bent to shape). Oil level should be 0.157" (4 mm) +/-.039" (1 mm) below bottom lip of oil filler hole. Fill up with gear oil if necessary. Gear Oil Specification: SAE 75 W 90 (synthetic oil), Part number G 00 500 0. Fit oil filler plug to 30 ft. lbs. (40 N.m).
12. Observe safety precautions after connecting the battery. See «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01e-awd__battery-disconnect-precautions).
13. After connecting battery, enter anti-theft code for radio. Close windows fully using electric window switches. Operate all electric window switches again for at least one second in "close" direction to activate automatic one-touch function. Set clock to correct time.

Information not available from manufacturer.

Information not available from manufacturer.

Scheme 157

Scheme 158

Scheme 159

See also:
• DRIVESHAFT & UNIVERSAL JOINTS
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• BATTERY DISCONNECT PRECAUTIONS
• CLUTCH PEDAL & OVERCENTER SPRING
• CLUTCH HYDRAULIC SYSTEM
• DUAL-MASS FLYWHEEL & PILOT NEEDLE BEARING
• ADJUSTING SAC PRESSURE PLATE