Overhaul - 01l (awd) Audi A6 C5

IDENTIFICATION

TRANSMISSION APPLICATION

TRANSMISSION

The 5-speed automatic transmission 01L is installed in the Audi A6 in combination with 8 cylinder engines.

Location On Transmission

The identification plate (arrow) is located in front of the oil pan on the bottom of the side of the transmission. (Scheme 205)

Scheme 205

Note. The code letters of the transmission are also listed on the vehicle data plate.

Scheme 206

Scheme 207

Notes

1. Before attempting to repair the transmission check DTC memory first.
2. When dealing with problems relating to poor acceleration and performance or general malfunctions, the following chart indicates which selector elements are actuated in the various transmission ranges. This should help to identify the selector elements which are not working properly.
3. If not otherwise described, the clutch and solenoid valve logic in the respective selector lever positions is the same as for the permanent driving range D.

Scheme 208

1. A = Clutch A
2. B = Clutch B
3. C = Clutch C
4. D = Brake D
5. E = Brake E
6. F = Brake F
7. F1 = Freewheel 1
8. W = Torque Converter
9. Z1 To Z3 = Spur Gears (intermediate drive front)
10. Z4, Z5 = Ring gear and pinion (front final drive)
11. Z6, Z7 = Spur gears for intermediate drive rear
12. Z6, Z7 = Spur gears for intermediate drive rear
13. 1 = Driving direction
14. 2 = Front axle differential
15. 3 = Front axle drive
16. 4 = Rear axle drive
17. 5 = Torsen differential
18. 6 = Rear differential

Solenoid Valves

SOLENOID VALVE & PRESSURE REGULATOR VALVE APPLICATION (1)

Clutches

CLUTCH APPLICATION (1)

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (01L, AWD) article.

AXLE SHAFTS

For information on axle shafts, see AXLE SHAFTS - FRONT & REAR article.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T (01L, AWD) article.

GENERAL REPAIR INSTRUCTIONS

Maximum possible care and cleanliness, as well as proper tools, are essential for satisfactory and successful transmission repairs. Also, the generally applicable basic rules of safety naturally apply when performing repair work.

1. Do not run the engine or tow the vehicle if the oil pan is removed or if there is no ATF in the transmission.
2. When exchanging the automatic transmission, the levels of the ATF in the planetary gearbox and the gear oil in the final drive must be checked and corrected if necessary.
3. Capacities and specifications. See «SERVICING - A/T (01L, AWD)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd) article.
4. Before installing the transmission, check the installation dimension of the torque converter. See «TORQUE CONVERTER, INSTALLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__torque-converter-installing) .
5. When installing the transmission, make sure that the dowel sleeves are correctly seated.
6. When the transmission is removed, secure the torque converter to prevent it from falling out of the transmission.
7. Thoroughly clean connection points and surrounding areas before disconnecting.
8. Place removed parts on a clean surface and cover them with foil or paper. Do NOT use cloths with lint!
9. Carefully cover or close open components if repairs are not to be carried out immediately.
10. Install only clean parts. Do not remove replacement parts from their wrapping until just before installing them.
11. Rules for cleanliness when working on the automatic transmission. See «Rules For Cleanliness When Working On Automatic Transmission»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__rules-of-cleanliness-when-working-on) .

O-RINGS, SEALS, GASKETS

1. Always replace sealing rings and gaskets.
2. After removing gaskets, always inspect the contact surface on the housing or shaft for burrs resulting from removal and for signs of damage.
3. Coat O-rings with a thin coat of ATF at outer circumference and at sealing lip before installing.
4. Coat sealing rings with ATF or Vaseline before inserting in order to avoid pinching of the rings during installation.
5. Never use other lubricants in surrounding area of the ATF. Otherwise danger of improper functioning of the hydraulic transmission control may occur.
6. The open side of each sealing ring faces the fluid to be sealed.
7. After installing, check the gear oil and ATF levels, and correct if necessary.

CIRCLIPS

1. Do not over-stress circlips, replace if necessary.
2. Circlips must be properly seated in their grooves.

NUTS, BOLTS

1. Bolts and nuts attaching housings and covers or the valve body must be loosened and tightened in stages in accordance with the specified tightening sequence or method.
2. Loosen bolts and nuts in a sequence opposite to the tightening sequence.
3. If no tightening sequence is specified, bolts and nuts attaching housings and covers must be loosened and tightened in stages and in an alternating diagonal pattern.
4. Tightening torques specified in repair procedures are for non-lubricated nuts and bolts.
5. The threads of bolts which are coated with locking fluid must be cleaned with a wire brush and coated with AMV 185 100 A1 before installation.
6. Always replace self-locking nuts.

BEARINGS

1. Install needle bearings with the inscribed side (thicker metal) facing the drift.
2. Insert bearings into transmission using ATF. Oil with special care for friction torque measurements.
3. Do not interchange outer and inner rings with the same bearing diameter.
4. Always replace tapered roller bearings which are installed on one shaft as a set from a single manufacturer.

ADJUSTMENT SHIMS

1. Measure adjustment shims in several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely.
2. Check for burrs or damage. Only install adjustment shims which are in perfect, undamaged condition.

ON BOARD DIAGNOSTIC (OBD)

Before carrying out repair work on the automatic transmission, determine the cause of the malfunction as precisely as possible. See appropriate DIAGNOSIS - 01L, AWD article.

TORQUE CONVERTER

1. Observe rules of cleanliness when working on the automatic transmission. See «RULES OF CLEANLINESS WHEN WORKING ON AUTOMATIC TRANSMISSIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__rules-of-cleanliness-when-working-on) .
2. General repair instructions. See «GENERAL REPAIR INSTRUCTIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__general-repair-instructions) .
3. Lubricate seals with ATF or Vaseline. Other lubricants may lead to problems in the hydraulic controls of the transmission.

Special Tools & Equipment

1. VW 681 - extractor lever
2. 3455 - Installation drift (Scheme 209)

Scheme 209

Replacing

Remove transmission. See REMOVAL & INSTALLATION - A/T (01L) article.

Install transmission in repair fixture, or place on level ground.

Carefully pull out torque converter.

Remove circlip -item. 2. (Scheme 210)

Scheme 210

Remove seal with extractor lever VW 681. (Scheme 211)

Scheme 211

1. Position extractor lever VW 681 directly behind sealing lip to avoid damaging wave washer -item. 4. (Scheme 210)
2. Replace wave washer if damaged.
3. Replace circlip if damaged.

Install seal to stop using installation drift 3455. (Scheme 212)

Scheme 212

Insert circlip in groove.

1. The open side of the seal points toward the transmission. Lightly lubricate outer rim of seal and sealing lip with Vaseline.
2. Before installing seal be sure that the wavy washer -item. 4, (Scheme 210) was not damaged and was installed properly.
3. The circlip must be seated in the bottom of the groove.

TORQUE CONVERTER, CHECKING

Check hub -arrow- of converter for grooves. (Scheme 213)

Scheme 213

Note. A faulty or damaged torque converter must be replaced.

TORQUE CONVERTER, INSTALLING

Insert torque converter through seal to first stop on transmission shaft.

Push converter by hand into bell housing while turning converter until notches on converter hub engage with corresponding driver notches of pump wheel and converter slides noticeably toward inside.

Installing Dimension

The torque converter was correctly installed when the distance between the flange of the bell housing and the threaded plates at the converter is approx. 22 mm. (Scheme 214)

Scheme 214

If the converter was not properly installed, this dimension is approx. 10 mm.

AUTOMATIC TRANSMISSION - OVERHAUL

Note. Complete overhaul procedures are not available from manufacturer.

Rules Of Cleanliness When Working On Automatic Transmissions

1. Thoroughly clean connecting points and the area around them before separating.
2. Place parts that have been removed on a clean surface and cover them. Use paper or foil. Do not use rags that can leave lint.
3. Carefully cover or close components that have been opened if repair will not be done immediately.
4. Install only clean parts. Only remove replacement parts from packaging when they are ready to be installed.
5. Always replace O-rings, sealing rings and gaskets.
6. Lubricate O-rings with ATF or Vaseline when installing to prevent tearing them during assembly.
7. Lightly lubricate sealing rings on the outside and on the sealing lip with Vaseline.
8. As a general rule, do not use any other lubricants for parts coming in contact with ATF, otherwise the hydraulic function of the transmission will be impaired.
9. After installation of transmission, check ATF level and top up if necessary.

Removal & Installation

Remove oil pan and ATF screen. See TRANSAXLE OIL PAN & ATF SCREEN in SERVICING - A/T (01L, AWD) article.

Remove circlip (arrow) for harness connector. (Scheme 215) Remove harness connector by pressing toward inside.

Scheme 215

Valve body bolts have different lengths. Remove bolts (arrows). (Scheme 216) Carefully remove valve body from transmission.

Scheme 216

To install, lightly lubricate "O" ring for harness connector with petroleum jelly or equivalent. Install harness connector in transmission. Tabs on connection side must be horizontal.

Flattened side of connector must be positioned parallel to oil pan sealing face. Fasten and route harness at valve body. See TRANSAXLE WIRING HARNESS .

Attach valve body without force, and insert dowel of indent (1) into groove of selector lever (2). (Scheme 217)

Scheme 217

Insert harness connector circlip (arrow). (Scheme 215)

Install valve body bolts (arrows), and hand tighten. (Scheme 216) Bolts have different lengths. Ensure correct bolts are used during installation.

Tighten valve body bolts and remaining nuts and bolts to 71 INCH lbs. (8 N.m).

Scheme 218

Install oil pan and ATF screen. See TRANSAXLE OIL PAN & ATF SCREEN in SERVICING - A/T (01L, AWD) article.

Scheme 219

Scheme 220

1. Using a small screwdriver, pry out retaining tabs on solenoid valve connectors, and pull off connectors. (Scheme 219) Remove harness from side clips of valve body. Remove sensor for transmission RPM (A) on back side of valve body. (Scheme 220) Carefully bend out both clips (arrows) with pair of pliers.
2. To install, reverse removal procedure. When installing wiring harness, plug connectors onto respective solenoid valves. Clip wiring harness into retaining clips. If not installed correctly, wiring harness can be trapped when valve body is installed.
3. Replace damaged clamps Install valve body.

Special Tools And Equipment

1. VAG 1383 A Engine/transmission hoist with VAG 1359/2 transmission support.

Removing Drive Shaft

Remove rear part of exhaust system behind clamping sleeve(s).

Check whether there is a factory marking (color marking) on drive shaft. If not, mark location of drive shaft flange (arrow -A-) to rear final drive (arrow -B-) with color. (Scheme 221)

Disconnect drive shaft from rear final drive and tie up at exhaust system clamps.

Scheme 221

Removing & Installing Rear Final Drive

Remove heat shields from final drive (arrows). (Scheme 222) Disconnect left and right drive axles and rest them on suspension links.

Scheme 222

Remove nuts (arrows) from bonded rubber bushings at rear subframe. The bolts remain inserted. (Scheme 223)

Scheme 223

Place VAG 1383A engine/transmission hoist with 1359/2 transmission support under final drive and support final drive. (Scheme 224)

Scheme 224

Remove securing bolts (arrows) of left final drive support. (Scheme 225) Slide bolts through the bonded rubber bushings of rear crossmember. Lower final drive.

Scheme 225

Installation is reverse of removal procedure. Tighten fasterners to specification. (Scheme 226)

Installing Driveshaft

Installation is reverse of removal, noting the following

1. Always replace self-locking nuts.
2. Always clean any remaining locking fluid from thread for drive flange on rear final drive after removing drive shaft. Otherwise there is a possibility that the new bolts may get jammed when installed and shear when removed again. Cleaning can be performed with a thread cutter.
3. Replace drive shaft bolts (self-locking).
4. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled.
5. Replace seals at drive flange (remove protective film and attach gasket to drive flanges).
6. In order to avoid imbalance, the flanges must be installed so that the color markings (arrows) -A- and -B- line up. (Scheme 221)

Top off transmission fluid in rear final drive and check oil level. See SERVICING - A/T (01L, AWD) article.

Install exhaust system free of stress.

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

1. VAG 1306 Drip tray

Removing (Rear Differential)

1. Rear final drive removed from vehicle. See «REAR FINAL DRIVE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd) .

Secure entire final drive in VW540 holding fixture.

Place drip tray underneath.

Drain gear oil.

Remove left and right drive flanges. To loosen securing bolt, thread in 2 bolts into drive flange and counter hold with tire iron. (Scheme 228)

Mark left and right drive flanges and pull out.

Remove mounting bolts for final drive cover.

Remove final drive cover from axle housing and remove differential.

Installing

Installation is the reverse of removal.

Install differential.

Replace O-ring for final drive cover and oil for installation.

Install final drive cover onto final drive housing and tighten in diagonal pattern to 25 Nm.

Lubricate area between sealing lip and dust lip with a thin layer of multi-purpose grease.

Install drive flanges and tighten to 25 Nm.

Top off transmission fluid in rear final drive and check oil level. See SERVICING - A/T (01L, AWD) article.

Scheme 231

Scheme 232

Scheme 233

1. VW401 Thrust plate
2. VW402 Thrust plate
3. VW407 Punch
4. VW412 Punch
5. VW295 Needle bearing drift
6. VW408A Punch
7. VW442 Thrust pad
8. 40-21 Sleeve
9. 40-105 Thrust piece
10. 2050 Thrust plate
11. 3138 Drift
12. Kukko 44/2 Two-arm puller
13. VAG 1582 Taper roller bearing puller
14. VAG 1582/6

Scheme 234

Scheme 235

Check adjustment shims for damage after removing.

Scheme 236

Scheme 237

Pressing On Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, place on and then press on. (Scheme 238)

Scheme 238

Pulling Off Double Tapered Roller Bearing Inner Race

Before installing, set 40-105 thrust piece onto differential housing. (Scheme 239)

Scheme 239

Pressing On Double Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, place on and then press on. (Scheme 240)

Scheme 240

Scheme 241

Check adjustment shims for damage after removing.

Scheme 242

Scheme 243

Installing Ring Gear

Guide ring gear with centering pins -A- (local manufacturer) when installing ring gear. (Scheme 244)

Scheme 244

Heat inner race to approx. 100° C and insert.

Install Differential Bevel Gears

If the large differential bevel gears were replaced, adjustment shims must be re-determined.

Insert large differential bevel gears with determined adjustment shims.

Install small differential bevel gears at 180° from their final position and rotate into place (arrow). (Scheme 245)

Scheme 245

Install thrust washers and locate.

Install threaded pieces.

Drive in differential bevel gear shaft to final position and secure.

Differential Bevel Gears, Adjusting

Install large differential bevel gears with the thinnest shims (0.5 mm). (Scheme 246)

Scheme 246

Install small differential bevel gears rotated by 180 together with thrust washers.

Note. Do not rearrange differential bevel gears and thrust washers again!

Drive in shaft for differential bevel gears.

Press small differential bevel gears toward outside.

Push large differential bevel gears in direction of arrow and check play.

Determine thickest possible shim that can still be inserted for large differential bevel gears on each side.

Select adjustment shims of same thickness.

Determine adjustment shims according to table. (Scheme 247)

Scheme 247

Note. The adjustment is also correct when no more play is present and the differential bevel gears can just barely be rotated (arrow). (Scheme 248)

1. VAG 1383A Engine/transmission hoist
2. VAG 1359/2 Universal mount
3. VW391 Puller
4. VW401 Thrust plate
5. VW402 Thrust plate
6. VW408A Punch
7. VW412 Punch
8. VW457 Support channels
9. VW460/2 Drift
10. VW470/1 Thrust shell for drive pinion bearing
11. VW540 Holding fixture
12. VW771 Slide hammer-complete set with 771/37
13. 30-205 Thrust pad
14. 2003/3 Seal installer
15. 3005 Thrust pad
16. 3026 Mandrel
17. 3028 Retainer
18. 3062 Thrust pad
19. 3138 Drift
20. 3143 Seal driver
21. 3253 Wheel bearing assembly set with 3253/3 and 3253/4
22. Kukko 17/2 Separator
23. Kukko21/7 Extractor
24. Kukko 22/2 Support
25. Torque gauge (0-600 Ncm)
26. 36 mm long socket

Scheme 248

Removing Drive Pinion Nut

Thread in two hex head bolts M8 x 30 -A-. (Scheme 250)

Scheme 249

When nut is removed, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).

Pull Off Driveshaft Flange From Drive Pinion

Thread two hex head bolts M8 x 30 -A- into flange. (Scheme 251)

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Check adjustment shims for damage after removing.

Scheme 255

Pressing Large Tapered Roller Bearing Inner Race Onto Drive Pinion

Heat inner race to approx. 100° C, place on and then press on. (Scheme 257)

Scheme 256

Pressing In Double Tapered Roller Bearing Outer Race

Before installing, install drive pinion shim S3 determined in earlier step. See Adjustment Overview .

Scheme 257

Note. On 3253/4 pressure disc, marking "Oben" points toward nut on installation device.

Pressing In Tapered Roller Bearing Outer Race

Install oiled outer race and using VW408A punch and 30-205 thrust pad. (Scheme 259)

Scheme 258

Insert drive pinion with a new spacer sleeve.

Heat up small tapered roller bearing inner race to approx. 100° C and insert on drive pinion.

Press drive pinion upward and insert bearing up to stop using 40-21. (Scheme 260)

Scheme 259

Replacing O-Ring (Drive Pinion)

Insert O-ring with gear oil. (Scheme 261)

Scheme 260

Driving In Seal For Driveshaft Flange

Lightly oil outer circumference of seal.

Lubricate area between sealing lip and dust lip with a thin layer of multi-purpose grease.

Drive seal in to stop using 3026 pressure piece. (Scheme 262)

Scheme 261

Installing Flange

Drive flange for drive shaft far enough onto drive pinion so that securing nut can be installed. (Scheme 263)

Scheme 262

Tightening Drive Pinion Nut And Adjusting Friction Torque

Thread in two hex head bolts M8 x 30 -A-. (Scheme 250)

When nut is tightened, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).

Note. Increase torque slowly and measure friction torque multiple times. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.

Measuring Friction Torque

With torque gauge, 0 to 600 Ncm, locally available. (Scheme 264)

Scheme 263

Note. If necessary use 3/4" to 1/2" reducing piece.

Adjust to following friction torque. (Scheme 265)

Scheme 264

Securing Drive Pinion Nut

After nut has been secured, radial run-out at driveshaft flange must be measured. See Measuring Driveshaft Radial Runout .

Scheme 265

Measuring Driveshaft Radial Runout

Radial run-out must always be measured if the flange drive shaft at rear final drive was removed. Make new color marking and remove old color marking.

If a new drive shaft is installed and the color marking on the drive flange of the rear final drive is no longer visible, location of largest radial run-out must be determined and marked with a color marking. Align this colored dot with colored dot on drive shaft.

Radial run-out can be measured with the rear final drive installed, however the drive shaft must be disconnected from the rear final drive.

Scheme 266

1. Attach VW387 dial gauge holder with dial indicator to connection between crossmember and final drive. (Scheme 267) Set dial indicator onto ground diameter -arrow- in drive shaft flange and set to "0" with 1 mm preload.
2. Turn differential via both rear wheels (right and left drive flanges) in one direction until the drive shaft flange has made one complete revolution.
3. Mark largest radial run-out on outer edge of flange with colored marking (equivalent to largest distance from turning axis). Remove old marking on drive shaft flange.

DRIVE PINION & RING GEAR, ADJUSTING

1. Drive pinion and ring gear must be very carefully adjusted to ensure long service life and smooth running. At the factory, drive pinion and ring gear are adjusted relative to each other to ensure smooth running and low noise in both directions. The location for the smoothest running is determined by moving drive pinion axially whereby ring gear is moved far enough out of the backlash-free position so that the backlash is within specified tolerances.
2. The goal of the adjustment is to reproduce the setting for the quietest possible running, as obtained on the test machine during production.
3. The deviation, or tolerance "r" which is based on the master gauge "R0" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. Every drive pinion set -drive pinion and ring gear - may only be replaced together.
4. Follow general repair notes for tapered roller bearings and shims.
5. Make sure that all installation and measurement procedures are performed with the utmost care and cleanliness to ensure a successful result.

Scheme 267

Gear Set, Adjusting Sequence

If drive pinion and gear ring have to be adjusted, the following sequence is recommended for maximum efficiency

1. Determine total shim thickness "Stot" (S total dimension) for S1 + S2 for the specified pre-tension of tapered roller bearings for differential.
2. Determine total shim thickness "S3" so that the drive pinion is installed in the same location as on the test machine during production.
3. Distribute total shim thickness S total S1 + S2, so that the specified backlash between ring gear and drive pinion is maintained.

Note. Overview of components and shims. See SHIM LOCATION .

Scheme 268

Scheme 269

DRIVE PINION, ADJUSTING

1. Before adjusting drive pinion, adjust ring gear (determine total shim thickness S total S1+S2). See «RING GEAR, ADJUSTING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__ring-gear-adjusting) .
2. Drive pinion only has to be adjusted if gear set, tapered roller bearings for drive pinion of final drive housing was replaced. See «Adjustment Overview»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd) .
3. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.

1. VAG 1383A Engine/transmission hoist
2. VAG 1359/2 Universal mount
3. VW385/1 Measuring bar
4. VW385/2 Plastic piece
5. VW385/3 Plastic piece
6. VW385/14 Measuring rod
7. VW385/15 Extension pin
8. VW385/17 Magnetic plate
9. VW385/30 Master gauge-adjustable
10. VW385/33 End gauge
11. VW387 Dial gauge holder
12. VW388 Measuring lever
13. VW401 Thrust plate
14. VW402 Thrust plate
15. VW408A Punch
16. VW457 Support channels
17. VW521/4 Locking sleeve
18. VW521/4 Locking sleeve
19. VW540 Holding fixture
20. 30-205 Thrust pad
21. 2003/3 Seal installer
22. 3005 Thrust pad
23. 3028 Retainer
24. 3062 Thrust pad
25. 3253 Wheel bearing assembly set with 3253/3 and 3253/4
26. Dial gauge extension 30 mm
27. Dial gauge
28. Torque gauge (0-600 Ncm)

Determining Shim "S3" (Drive Pinion)

Adjust preload of tapered roller bearing for drive pinion.

Clamp final drive into assembly fixture.

Install double tapered roller bearing outer race without shim into housing. (Scheme 258)

Note. On 3253/4 pressure disc, marking "Oben" points toward nut on installation device.

Pull small tapered roller bearing outer race into housing.

Install oiled outer race using VW408A punch and 30-205 thrust pad. (Scheme 259)

Install drive pinion without spacer sleeve.

Heat tapered roller bearing inner race to 100° C and install on drive pinion. (Scheme 260)

Note. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory. Only install spacer sleeve if friction torque has been adjusted (Shim S3 already determined).

A - Standard torque gauge, 0 to 600 Ncm. (Scheme 264)

Note. If necessary use 3/4" to 1/2" reducing piece.

Bolt in 3028 retainer using two hex bolts M8 x 30 -A-. (Scheme 250)

Tighten drive pinion nut to achieve following friction torque. (Scheme 265)

When nut is tightened, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).

Install adjustment ring from VW385/1 measuring bar. (Scheme 271)

1. Dimension a = 60 mm

Adjust sliding adjustment ring.

1. Dimension b = 55 mm

Scheme 270

Complete measuring bar as shown in illustration. (Scheme 272)

Scheme 271

1. VW385/15 extension pin 9 mm

VW385/30 master gauge, adjusting.

1. Ro = 57.50 mm

Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Note. Turn differential at least 5 rotations in each direction to seat the tapered roller bearings. Otherwise, measurement will result in false readings.

Install VW385/33 end gauge at drive pinion head. (Scheme 273)

Scheme 272

Remove master gauge and insert measuring mandrel into housing. (Scheme 274) VW385/3 plastic piece faces final drive cover

Scheme 273

Install cover for final drive and tighten four bolts.

Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.

Determining Dimension "e" (Drive Pinion)

Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head and measure maximum run-out (return point). Measured value is dimension "e" (red numbered area). (Scheme 275)

Scheme 274

Note. Measured value in the following example: "e" = 1.60 mm. Dimension "e" is required to determine thickness of S3 shim.

After removing universal mandrel, and with VW385/30 master gauge in place, check dial indicator again to see if it indicates 0 with 2 mm preload. If not, repeat measurement.

Scheme 275

Scheme 276

Determine shim as closely as possible according to table. (Scheme 278)

Scheme 277

Remove universal mandrel.

Remove drive pinion and large tapered roller bearing outer race and install together with determined shim S3 and spacer sleeve. See Removing Drive Pinion Nut .

Insert small tapered roller bearing inner race and tighten drive pinion nut until prescribed friction torque is attained. (Scheme 250)

Note. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory. Increase torque slowly and measure friction torque multiple times. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.

Adjust friction torque to following values. See DRIVE PINION FRICTION TORQUE table.

DRIVE PINION FRICTION TORQUE

Checking Dimension "r"

Rotate drive pinion at least 5 complete revolutions in both directions.

Install universal mandrel and perform check measurement. (Scheme 274)

If shims have been determined correctly, dial indicator must indicate deviation r with a tolerance of +/- 0.04 mm (reading counterclockwise in red number display).

Secure drive pinion nut using mandrel.

Note. Measure radial run-out at drive shaft flange and mark. See Measuring Driveshaft Radial Runout .

RING GEAR, ADJUSTING

Adjusting differential.

Procedures to be performed after ring gear is adjusted. See Adjustment Overview .

1. Tapered roller bearings for differential are low-friction bearings. Therefore friction torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "S total ".
2. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.

Total Shim Thickness Stotal For Shims S1 + S2, Determining (Ring Gear)

Adjust preload of tapered roller bearing for differential.

1. Drive pinion removed or ring gear detached from differential housing

Pry out drive flange seal using tire iron.

Remove tapered roller bearing outer races for differential and remove adjustment shims. See REAR DIFFERENTIAL, DISASSEMBLING & ASSEMBLING .

Press left tapered roller bearing outer race for differential (housing side) with adjustment shim "S2" into differential housing. See REAR DIFFERENTIAL, DISASSEMBLING & ASSEMBLING . Use a shim "S2*" with a 1.00 mm thickness for measurement purposes (1 shim with 0.80 and 1 shim with 0.20 mm).

Note. All measurements are performed with shim S2 of 1.00 mm thickness. The shim will be indicated by "S2*" in the following procedures. After determining backlash, S2* is replaced by final shim S2.

Drive in right tapered roller bearing outer race for differential (cover side) without adjustment shims up to stop. See REAR DIFFERENTIAL, DISASSEMBLING & ASSEMBLING .

Insert differential in housing. Ring gear is on the right side (cover side).

Install cover and tighten bolts to 25 Nm.

Install VW521/4 locking sleeve and 521/8 sleeve press tool onto housing side of differential housing. (Scheme 279) Rotate cover side of differential housing upward.

Scheme 278

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Place VW385/17 magnetic plate onto differential. Install measuring tools. (Scheme 280)

Scheme 279

Set dial gauge extension onto center of VW385/17 magnetic plate.

Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Lift differential without turning it, read backlash on dial indicator and note. (Scheme 281)

Note. Measured value in the following example: 0.50 mm.

Scheme 280

Note. If measurement is repeated, differential must first be rotated 5 complete revolutions in both directions again to seat tapered roller bearing.

Scheme 281

Determining Thickness Of Shim "S1*" (Ring Gear)

1. "S1*" is used for the initial measurement. After determining backlash, "S1*" is replaced with final shim "S1".
2. The total shim thickness "S total " remains unchanged.

Scheme 282

Calculate adjustment shims as accurately as possible according to the table. see scheme 86

Measuring Friction Torque (Check Measurement, Ring Gear)

1. Drive pinion removed
2. Differential installed with shims "S1*" and "S2*"

Torque gauge 0 to 600 Ncm -A- installed on differential. (Scheme 284)

Scheme 283

Read friction torque.

Friction torque specified values. See RING GEAR FRICTION TORQUE table.

RING GEAR FRICTION TORQUE

1. Tapered roller bearings for differential are low-friction bearings. Therefore friction torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "S total ".
2. Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
3. For a new adjustment of the gear set, the drive pinion adjustment must now be performed with checks. See «DRIVE PINION, ADJUSTING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01l-awd__drive-pinion-adjusting) .

Adjusting Backlash

Position of ring gear in transmission housing.

1. Drive pinion installed with shim S3
2. Differential installed with shims "S1*" and "S2*"

Insert differential in final drive housing, install cover and tighten all bolts to 25 Nm.

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Install measuring tools. (Scheme 285)

Scheme 284

Use VW382/10 extension pin, 6 mm.

Set VW388 measuring lever to dimension "a" = 60 mm.

Determine backlash between teeth flanks as follows

1. Turn ring gear until it contacts a tooth flank (end of backlash travel).
2. Set dial indicator to 0 with 1 mm preload.

Turn ring gear back until it contacts opposite tooth flank (backlash).

Read backlash and note.

Turn ring gear 90° every time and repeat measurement 3 times.

Note. If measurements vary more than 0.06 mm from each other, ring gear or gear set is not installed correctly. Check installation, replace gear set if necessary.

Scheme 285

Scheme 286

Determine shim as closely as possible according to table. (Scheme 288)

Scheme 287

Scheme 288

Determine shim as closely as possible according to table. see scheme 86

Scheme 289

Checking Measurement (Ring Gear Backlash)

1. Drive pinion installed with shim S3
2. Differential installed with shims "S1" and "S2"

Turn differential 5 rotations in each direction to seat the tapered roller bearing.

Measure backlash 4 times on circumference. (Scheme 285)

1. Specification: 0.12 to 0.22 mm

1. If backlash is outside tolerance, repeat adjustments. Do not change total shim thickness "S total " while doing so.
2. The individual measurement values can deviate a maximum of 0.06 mm from each other.

See also:
• SERVICING - A/T (01L, AWD)
• AXLE SHAFTS - FRONT & REAR
• REMOVAL & INSTALLATION - A/T (01L)
• TORQUE CONVERTER, INSTALLING
• Rules For Cleanliness When Working On Automatic Transmission
• GENERAL REPAIR INSTRUCTIONS
• TRANSAXLE WIRING HARNESS
• Measuring Driveshaft Radial Runout
• RING GEAR, ADJUSTING
• Removing Drive Pinion Nut
• DRIVE PINION, ADJUSTING