Manual Transmission - Servicing - M/t (5-speed, 01a) Audi A4 B6

TRANSAXLE

This article applies to 2002-2004 A4 models with all wheel drive and the 1.8L or 3.0L 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 35)
2. Manual transmission 01A (arrow 2). (Scheme 35)
3. Code letters (arrow 3). (Scheme 35)
4. Code letters and date of manufacture (arrow). (Scheme 36)

Scheme 35

Scheme 36

SERVICE INTERVALS

No oil changes are required.

CHECKING FLUID LEVEL

The vehicle must be level for checking the oil level. An inspection pit or 4-pillar lifting platform are the most suitable methods.

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

Remove oil filler plug. (Scheme 37) 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 37

RECOMMENDED FLUID

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

FLUID CAPACITIES

TRANSMISSION REFILL CAPACITIES

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". Connect scan tool to DLC. 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.
7. To switch off emergency battery, select/press button 3 - "Service mode activating (no load on emergency battery)". Follow the tester's prompts.

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.

Shift Mechanism: 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 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

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 38)
2. Release connector piece (1) in direction of arrow and pull off shift lever knob together with shift lever cover upward. (Scheme 39)
3. Lift off trim (1) first in direction of arrow (A) and then pull out in direction of arrow (B). (Scheme 40)
4. Remove bolts (arrows C) and then pull ashtray (2) from center console. (Scheme 40)
5. Lift up damping washer (1) and noise insulation (2) upward. (Scheme 41)
6. Remove noise insulation from shift lever housing (arrows). (Scheme 42)
7. Measure distance (a) between the two studs in shift mechanism. Measurement is from center of stud to center of stud. (Scheme 43) Specification: Dimension (a) = 85 mm.
8. In case of deviation, adjust distance (a) as follows: Loosen bolt (arrow) for push rod. (Scheme 43) 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 44) The selector rod and shift mechanism connection must move freely.

Scheme 45

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 45)
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 44) 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 46

1. Remove heat shield (arrow 2) above right drive axle. (Scheme 46) Detach heat shield (arrow 1) above right drive axle and pivot downward. (Scheme 46)
2. Remove gear lock (arrow). (Scheme 47)

Scheme 47

Scheme 48

Scheme 49

1. Insert spring (1) into housing (2) and, while applying light pressure, turn spring to left until it locates in base of housing. (Scheme 48)
2. Insert bushing (3) onto spring so bent end of spring locates into groove properly. (Scheme 48)
3. Push bushing against spring and turn approx. one turn counterclockwise, until lug on bushing aligns with groove in housing. Press lug of bushing into groove in housing onto stop.
4. Turn bushing clockwise and release. The bushing will spring into the correct position.
5. Lug (arrow A) of bushing must always face away from groove in housing (arrow B). (Scheme 49)
6. Checking installation position: Turn bushing counterclockwise and release. The bushing should spring back into position; the lug must be against the stop, (direction indicated by arrow A). (Scheme 49)
7. Installation position of complete gear lock in transmission: The recess (arrow A) faces bolt (arrow B). (Scheme 50)

REMOVAL & INSTALLATION

AXLE SEALS

Note. This procedure is performed with transmission installed.

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Turn steering to full left lock. Remove cover plates over right drive shaft (arrows 1 and 2). (Scheme 51) If installed, remove cover plate over left drive shaft. Unbolt drive shaft from flange on transmission. Tie up drive shaft as high as possible. Do not damage paint on drive shaft. Place drip tray VAG 1306 underneath the transmission.
2. Remove left flange shaft; by screwing puller T10037 to differential cover (arrow). (Scheme 52)
3. Remove right flange shaft, by screwing puller T10037 to transmission housing (arrow). (Scheme 53)
4. 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 54)
5. Remove drive flange seal using VW681 extractor lever.
6. To assemble flange shaft with polygon (needle) bearings (Scheme 55) If polygon (needle) bearings are used, check them for cracks, excessive wear and damage. (Scheme 55)

Installation

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

Scheme 54

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 56) NOTE: If reinstalling an old drive flange, the seal must be pressed in approximately 6.5 mm (0.256 in.) so that the new seal does not sit on the running surface of the old seal.
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/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__checking-fluid-level).

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Place drip tray VAG 1306 underneath and drain gear oil. Separate exhaust system at clamp -1-. (Scheme 57)
2. Unscrew heat shield for drive shaft from cover of Torsen differential -arrows-. (Scheme 58)
3. Unscrew drive shaft from transmission. Re-insert speed nut -arrow- slightly and secure drive shaft to stud with wire. (Scheme 59) Place drip tray VAG 1306 below cap.
4. Remove circlip -A-. (Scheme 60) Install an M8 bolt into threaded hole of cap. (Scheme 60) Remove cap -B- by means of bolt. Oil escapes when cap -B- is taken off.
5. Expand circlip and pull out drive flange. (Scheme 61)
6. Pull out oil seal for drive flange using VW 681. (Scheme 62)

Scheme 60

1. Slightly oil circumference of oil seal. Drive in new oil seal for drive flange 2 mm below surface of housing, taking care not to tilt it. (Scheme 63) Fill space between sealing lip and dust lip with sealing grease G 052 128 A1.
2. Insert drive flange. Insert drive flange circlip at same time as shaft. (Scheme 61) Circlip must be properly positioned in groove. Insert cap with a new O-ring and secure.
3. Install driveshaft to transmission.
4. Top off and check transmission oil level. See «CHECKING FLUID LEVEL»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__checking-fluid-level).
5. Align exhaust system free of stress.

SHIFT MECHANISM

To identify shifter mechanism components. see scheme 30, see scheme 31 and see scheme 32.

Scheme 61

Scheme 62

Scheme 63

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

Scheme 64

Scheme 65

Scheme 66

1. Lift cover of center console upward -arrows- and off. see scheme 33 Release connection piece -1- in direction of arrow and pull gear shift knob together with gear shift cover upward to remove. see scheme 34 Remove gear shift knob together with gear shift cover and cover of center console.
2. First lift cover -1- up in direction of arrow -A- and pull out in direction of arrow -B-. (Scheme 64) Unscrew bolts -arrows- C- and then remove ashtray -2- from center console.
3. Lift damping washer -1- and noise insulation -2- upward and out. (Scheme 65)
4. Unscrew noise insulation for gear shift housing -arrows-. (Scheme 65). Unscrew securing nuts -arrows- for gear shift housing.
5. Unscrew noise insulation for shift housing -arrows-. (Scheme 66) Unscrew securing nuts -arrows- for gear shift housing. (Scheme 67) This lowers the gear shift housing.
6. Unscrew heat shield for drive shaft from Torsen differential housing -arrows-. (Scheme 68)
7. Detach exhaust system from clamp(s) -1- onward. (Scheme 69) Unscrew drive shaft -2- from transmission and secure at side with wire. (Scheme 70) Remove driveshaft. Remove heat shield -3- above exhaust system -arrows-. (Scheme 69)
8. Re-insert speed nut which was previously removed -arrow- and attach drive shaft to it with a wire. (Scheme 70)
9. Remove gearshift linkage -arrow A-. (Scheme 71) Unscrew hex socket head bolt of push rod -arrow B-. Swivel shift lever housing with selector rod and push rod downward and remove.

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

Scheme 67

1. Install in reverse order. Push on gearshift linkage until bolt is located in counterbore of selector shaft.
2. Screw selector rod firmly in place (arrow -A-). (Scheme 71) Screw push rod securely to transmission (arrow -B-).
3. Install heat shield -3- above exhaust system -arrows-. (Scheme 69) Screw drive shaft -2- to transmission. Secure exhaust clamp(s) -1-. (Scheme 69)
4. Secure heat shield for drive shaft to Torsen differential housing -arrows-. (Scheme 68) Adjusting shift mechanism. See «SHIFT MECHANISM»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__shift-mechanism).
5. Position gear shift knob together with gear shift cover on gear shift and turn connection piece -1- in direction of arrow as far as it will go. (Scheme 72)

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 44 Press retaining clip down, turn sensor sideways and remove upward. Installing: Replace O-ring -B-. see scheme 44 Install sensor and lock into place.

Scheme 68

VEHICLE SPEED SENSOR DRIVE WHEEL

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

Scheme 69

1. Turn steering to full left lock. Raise and support vehicle. If installed, remove cover plate over left drive shaft. Unbolt drive shaft from flange shaft. Place drip tray underneath.
2. Remove flange shaft; by screwing puller T10037 to differential cover (arrow). (Scheme 52) Pull out flange shaft oil seal with VW 681. See «AXLE SEALS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__axle-seals).
3. Remove Vehicle Speed Sensor (VSS). See «VEHICLE SPEED SENSOR»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__vehicle-speed-sensor).
4. With a screwdriver press retaining clips in direction of arrows. see scheme 45 Remove drive gear by prying out, alternating between sides.

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 46 The retaining clips (arrows) lock in the circumferential groove in the differential. see scheme 46 Always replace seal -B- and circlip -C-. See «AXLE SEALS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a__axle-seals). Drive in drive flange using VW295 needle bearing drift.
2. Check transmission oil level. Top off to lower edge of fill hole, if necessary. See «LUBRICATION»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a). Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-5-speed-01a).

Scheme 70

Scheme 71

Scheme 72

See also:
• RECOMMENDED FLUID
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• BATTERY DISCONNECT PRECAUTIONS
• CHECKING FLUID LEVEL
• SHIFT MECHANISM
• AXLE SEALS
• VEHICLE SPEED SENSOR