Manual Transmission - Servicing - M/t (6 Speed, 01e) Audi A4 B6

TRANSAXLE

This article applies to 2002-2004 A4 models with 6 Speed All Wheel Drive.

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. For identification locations on transaxle, see list below.

1. Code letters and consecutive serial numbers (arrow 1). (Scheme 73)
2. Manual transmission 01E (arrow 2). (Scheme 74)

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

Scheme 73

Scheme 74

SERVICE INTERVALS

No oil changes are required.

CHECKING FLUID LEVEL

Note. When checking the oil level in the transaxle, the vehicle should be standing on a perfectly horizontal surface. An inspection pit or a 4-post lifting platform is ideal. The prescribed oil level is to be adhered to exactly; the transmission reacts very sensitively to over-filling.

Note. If a transmission with transmission oil cooling has been removed, the vehicle must be driven a short distance on the road before checking the transmission oil level.

Check oil level in transaxle. Remove oil filler plug (B), (in front of drive flange) to check transmission oil level. (Scheme 75)

Check oil level with a suitable tool (such as a length of wire bent to shape). Vehicles with V6 bi-turbo engine: oil level should be 0.276" +/-.039" (7 mm +/- 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 and tighten to 30 ft. lbs. (40 N.m). (Scheme 75)

Scheme 75

RECOMMENDED FLUID

Manufacturer recommends SAE 75W-90. Part number G 052 911, a 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. 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 (AUDI TELEMATICS)

Note. This procedure requires using factory scan tool, or equivalent aftermarket scan tool.

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.
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.

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 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Remove shift knob with cover. Unclip cover for center console and lift this out upward -arrows-. (Scheme 76)
2. Detach connecting part -1- in direction of arrow and pull off shift knob together with shift lever cover upward. (Scheme 77)
3. Vehicles with large radio compartment. Remove A/C control head. See «A/C CONTROL HEAD»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__ac-control-head).
4. Vehicles with small radio compartment: Lift panel -1- first in direction of arrow -A- and pull out in direction of arrow -B-. (Scheme 78)
5. Vehicles with large and small radio compartment: Unscrew the bolts -arrows C- and pull out the ashtray -2- from the center console. (Scheme 78) Disconnect electrical harness connector for ashtray lighting. Remove foam wedges from center console. Lift out the upper noise insulation upward.
6. Unscrew lower noise insulation cover for shift lever housing -arrows-. (Scheme 79)
7. Measure distance -a- between the two threaded studs in the shift lever mechanism. (Scheme 80) Specified value: Distance a = 0.335" (85) mm.
8. If this is not the case, adjust distance -a- as follows: Loosen push rod bolt (arrow). (Scheme 80) 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 81

1. Align the shift lever as follows: Loosen bolt for selector rod -arrow-. (Scheme 81) 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 82)
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 81)

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.

Radio Removal & Installation

Special tool T10057 is used in removing all radios. (Scheme 83)

Scheme 82

Note. This procedure is for removing and installing the radio only. DO NOT disconnect the wiring if at all possible.

For removal of the different models of radios, see list below.

Scheme 83

Scheme 84

Scheme 85

1. Removing "Concert ll" radio. (Scheme 84)
2. Removing "Symphony ll" radio. (Scheme 85)
3. Removing CD changer. (Scheme 86)
4. Installing radio or CD changer: Carefully insert the radio into the instrument panel and let it engage in the installation slot.

REMOVAL & INSTALLATION

A/C CONTROL HEAD

Note. This information is for vehicles without Radio-Navigation system or radio with large control panel.

Scheme 86

1. If A/C control head wiring needs to be disconnected, see «BATTERY DISCONNECT PRECAUTIONS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__battery-disconnect-precautions).
2. The A/C control head is secured in the center console with 4 retaining clips -A-. (Scheme 87) When installing an A/C control head observe exact allocation (e.g. with or without switch for heated seats).
3. Reach from below in the center console and loosen A/C control head from center console. Remove radio or radio-navigation system.
4. Reach through the radio opening and push the A/C control head toward the rear out of center console.
5. Remove bolts -C- and slide trim -B- to the right and remove from A/C Control Head -A- (if installed). (Scheme 88)
6. Installation: Installation is in reverse order of removal.

AXLE SEALS

Note. This procedure is performed with transmission installed.

Scheme 87

Scheme 88

1. Remove shield, if installed, from underneath transmission.
2. When replacing left seal: If necessary, partially remove the front part of the exhaust system.
3. Continuation for both seals: Remove splash plate, if installed, above drive axles (arrows). (Scheme 89) Detach drive axles -1- from flanged shafts, and tie up as high as possible, do not damage surface protection. (Scheme 89)
4. Place drip tray underneath. Unscrew flanged shaft securing bolt; for this purpose, screw two bolts into the flange and counterhold the flanged shaft using a tire lever. Pull out flanged shaft.
5. Pull out flanged shaft seal with VW 681. See.

Installation

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

Scheme 89

1. Lightly oil outer circumference of seal. Drive in new seal for right-hand flanged shaft to a depth of 5.5 mm below surface of housing and for left-hand flange to a depth of 5.5 mm below surface of cover. (Scheme 91) NOTE: Do not cant seal when driving in. Insertion depth for repairs is 6.5 mm when a used flanged shaft is employed. NOTE: Figure shows installation on right-hand side of the transmission. The procedure is identical for left and right-hand seals.
2. Pack space between sealing and dust lips with sealing grease G 052 128 A1. Insert flanged shaft. Fasten flanged shaft with cone head bolt. Bolt drive axle to flanged shaft. Bolt on cover plates for drive axle if present.
3. If necessary, reinstall exhaust system and align free of stress.
4. Top up oil in transmission and check oil level. See «CHECKING FLUID LEVEL»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__checking-fluid-level). Install shield for underneath transmission if used.

Special Tools, Testers And Auxiliary Items Required

1. Drip tray V.A.G 1306
2. Adapter VW 295a
3. Thrust plate VW 401
4. Thrust plate VW 402
5. Press tool VW 407
6. Tube VW 415a
7. Tube VW 416b
8. Press tool VW 433
9. Thrust pad VW 454
10. Extractor lever VW 681
11. Multi-purpose tool 771/1 with attachment 771/15 and stud M8/M10
12. Punch 2005 and Shim, Part No. 016 311 391 B

Removal

To identify drive flange and bearing housing components. (Scheme 92)

Scheme 90

Note. This procedure is performed with transmission installed.

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Remove exhaust system from the clamps. (Scheme 93) Detach rear part of exhaust system from hangers and remove. NOTE: The flex joint in front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged. A second technician is required to remove the rear part of exhaust system.
2. Unbolt heat shield for driveshaft -arrows-. (Scheme 94) Remove bolts at flange of transmission/drive axle. Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
3. Secure driveshaft -1- with wire (arrow) to heat shield. (Scheme 95) Place container under the transmission. Unscrew rear oil drain plug (at end cover) and drain gear oil. Unscrew bolts attaching bearing housing.
4. Pull flanged shaft together with bearing housing and vibration damper off end cover. (Scheme 96) Remove bearing housing.
5. Remove circlip from flanged shaft. Press out flanged shaft. (Scheme 97)
6. Pull out flanged shaft seal. (Scheme 98) Thoroughly clean seat for seal.
7. Press out grooved ball bearing. (Scheme 99)

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Press grooved ball bearing in bearing housing. (Scheme 100)
2. Lightly oil outer circumference of seal -B-. Install seal together with washer -A-, Part No. 016 311 391 B (1.7 mm thick) onto drift 2005. Installation position: Open side of seal toward transmission. (Scheme 101)
3. Drive in flanged shaft seal. (Scheme 102) Remove washer after inserting seal. Pack space between sealing and dust lips with sealing grease G 052 128 A1. (Scheme 102)
4. Press in flanged shaft. (Scheme 103) Install circlip onto flanged shaft. Lightly oil O-ring and insert into groove of bearing housing. Insert dished washer and shims into bearing housing. Concave side of dished washer must face shims. Install spiral spring onto flanged shaft. (Scheme 103)
5. Tighten securing bolts for bearing housing in diagonal sequence and in stages to 25 Nm.
6. Bolt on driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01V & 01A (AWD TRANS)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle).
7. Top up oil in transmission and check oil level. See «CHECKING FLUID LEVEL»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__checking-fluid-level).

SHIFT MECHANISM

To identify shifter mechanism components. (Scheme 104)and (Scheme 105).

Scheme 101

Scheme 102

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

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

1. Unscrew shift knob from with cover.
2. Vehicles with large radio compartment: Remove A/C Control Head. See «A/C CONTROL HEAD»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__ac-control-head).
3. Vehicles with small radio compartment: Lift up panel -1- first in direction of arrow -A- and pull it out in the direction of arrow -B-. see scheme 34
4. All vehicles: Remove bolts -arrows C- and then remove ashtray -2- from center console. see scheme 34 Disconnect electrical harness connector for ashtray lighting. Remove foam wedges from center console. Lift out noise insulation upward.
5. Remove noise insulation cover for shift mechanism housing (arrows). (Scheme 106)
6. Unscrew nuts securing shift mechanism housing (arrows). (Scheme 107)
7. Disconnect exhaust system at double clamps -arrows-. (Scheme 108) Detach rear part of exhaust system on retaining loops and remove it.
8. Remove heat shield for driveshaft -arrows-. (Scheme 109)
9. Remove bolts at flange of transmission/driveshaft. Remove heat shield -1- -arrows-. (Scheme 110) Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially. Tie up the driveshaft -2- on transmission to the side. (Scheme 110)
10. Disconnect connecting rod -2- of shift rod. Remove pivot rod -1-, to do this unbolt socket-head bolts. (Scheme 111)
11. Remove nut -1- and pull transmission shift lever -2- from shift rod of transmission. (Scheme 112)
12. Remove VAG1359/2 universal mount from VAG1383A engine/transmission jack and place a piece of wood -arrow- onto punch instead. (Scheme 113) Support tunnel cross member using VAG1383A engine/transmission lift.
13. First remove bolts -1- and -2-, then bolts -3- and -4-. (Scheme 113) Remove shift mechanism toward rear.

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

1. Always replace gaskets and self-locking nuts. Install in reverse order of removal, noting the following
2. Install tunnel cross member: Tighten combi bolts -3- and -4- to 115 Nm plus an additional 90 degree turn. (Scheme 113) Tighten combi bolts -1- and -2- to 55 Nm. Tighten center combi nuts to 23 Nm.
3. Secure driveshaft to transmission. See «DRIVESHAFT & UNIVERSAL JOINTS - 01V & 01A (AWD TRANS)»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle).
4. Align exhaust system free of stress.
5. Adjust gear selector mechanism See «SHIFT MECHANISM»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__shift-mechanism).

VEHICLE SPEED SENSOR

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

Remove left front wheel. Remove splash plate above left drive axle -1- if installed (arrows). (Scheme 89)

Unplug connector from sender -B-. see scheme 43 Press retaining clip down, turn sender sideways and pull out upward.

Installing: Handle sender carefully. Replace O-ring -A-. If it is damaged it is possible that the speedometer will not indicate exactly. Tightening torque for heat shield for drive axle: 23 Nm

Scheme 110

VEHICLE SPEED SENSOR DRIVE WHEEL

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

Scheme 111

1. Partially remove front part of exhaust system. Remove shield, if installed, from underneath transmission. If installed, remove splash plate above left drive axle -1- (arrows). (Scheme 89) Unbolt drive axle from flanged shaft. Place drip tray underneath transmission.
2. Remove fastening screw -A- for flanged shaft -B-. see scheme 44 Pull out flanged shaft. Pull out flanged shaft seal -C- with VW 681. Remove speedometer vehicle speed sensor. See «VEHICLE SPEED SENSOR»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__vehicle-speed-sensor). Remove speedometer trigger wheel -D-. see scheme 44

Note. Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily.

1. Install drive wheel for vehicle speed sensor so that follower lugs (arrows) face toward seal. see scheme 44 Follower lugs engage in differential housing grooves.
2. Replace seal for drive flange and install drive flange. See «AXLE SEALS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e__axle-seals).
3. 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-6-speed-01e). Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/manual-trans/#manual-transmission-servicing-mt-6-speed-01e).

Scheme 112

Scheme 113

See also:
• DRIVESHAFT & UNIVERSAL JOINTS - 01V & 01A (AWD TRANS)
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• A/C CONTROL HEAD
• BATTERY DISCONNECT PRECAUTIONS
• TORQUE SPECIFICATIONS
• CHECKING FLUID LEVEL
• SHIFT MECHANISM
• VEHICLE SPEED SENSOR
• AXLE SEALS