Overhaul - 01v Audi A6 C5

IDENTIFICATION

TRANSMISSION APPLICATION

TRANSMISSION

The transmission code letters are given on the identification label at the bottom of the transmission. (Scheme 290)

Another identification label (identical to the first one) can be found on the side of the transmission. It is not accessible when the transmission is installed.

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

Transmission code letters and transmission serial number in (Scheme 290) are broken down as follows

1. Transmission serial no. (arrow -1-)
2. Transmission identification (arrow -2-)
3. Code letters (arrow -3-)

Scheme 290

TORQUE CONVERTER

The torque converter is equipped with a lock-up clutch. The closing (application) of the lock-up clutch is determined by the engine load and speed, and produces very little vibration. The lock-up clutch drives 3rd, 4th and 5th gears mechanically, independent of slip.

The 5-speed automatic transmission 01V has five hydraulically activated forward gears. When the lock-up clutch is applied these forward gears become mechanically driven gears by eliminating the torque converter slip.

HYDRAULIC CONTROL

A differentiation is made between two types of transmissions. Transmission with hydraulic control (valve body) E17, on which the sensor for transmission RPM (inductive sensor) is secured to the underside of the valve body. Transmission with hydraulic control E18/2, on which the sensor for transmission RPM (hall sensor is secured behind the valve body on transmission housing.

The information on which transmission and valve body are installed can be taken from the application table. See CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT .

ON BOARD DIAGNOSTIC (OBD)

See appropriate DIAGNOSIS - 01V article.

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (01V WITH 2.7L & 2.8L) article.

AXLE SHAFTS

For information on axle shafts, see AXLE SHAFTS - FRONT & REAR article in DRIVELINE/AXLES.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T (01V WITH 2.7L & 2.8L) article.

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

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. The engine may not be run with the oil pan removed or without ATF in planetary gear set, and the vehicle may not be towed.
2. When exchanging the automatic transmission, ATF in planetary gear set and differential as well as gear oil in final drive must be checked or topped up.
3. 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. Capacities and specifications. See «SERVICING - A/T (01V WITH 2.7L & 2.8L)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v) article.
4. Capacities and specifications. See «SERVICING - A/T (01V WITH 2.7L & 2.8L)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v) article
5. Check torque converter installation specification before installing the transmission. See «TORQUE CONVERTER, INSTALLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01v) .
6. When installing the transmission, make sure that the dowel sleeves are correctly seated.
7. Secure torque converter against falling out when transmission is removed.
8. Thoroughly clean connecting points and the area around them before separating.
9. Place parts that have been removed on a clean surface and cover them. Use foil or paper. Do not use cloths with lint!
10. Carefully cover or close components that have been opened if repair will not be done immediately.
11. Install only clean parts. Only remove replacement parts from packaging when they are ready to be installed.
12. Rules for cleanliness when working on the automatic transmission. See «Rules Of Cleanliness For Working On Automatic Transmissions»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01v__rules-of-cleanliness-for-working-on) .

O-RINGS, SEALS, GASKETS

1. Always replace O-rings, seals and gaskets.
2. After removing O-rings, check contact surface on housing or shaft for removal dependent burrs or damage.
3. Coat O-rings with ATF at outside circumference and at sealing lip for installation.
4. Coat O-rings with ATF or Vaseline when installing , to prevent pinching of the rings during installation.
5. Do not use any other lubricants in ATF area. Otherwise malfunctions of the hydraulic transmission control may occur.
6. The open side of the oil seals faces the fluid to be sealed in.
7. Check and if necessary top up transmission oil or ATF fluid after installing.

CIRCLIPS & RETAINERS

1. Do not over-stress circlips.
2. Replace if necessary.
3. 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. Bolts and nuts attaching housings and covers must be loosened and tightened evenly in stages and in an alternating diagonal pattern if no tightening sequence is specified.
4. Tightening torques specified in repair procedures are for non-oiled 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.

BUSHINGS, BEARINGS

1. Install needle bearings with the inscribed side (thicker metal) facing the drift.
2. Insert gears in transmission with ATF. Lubricate with special care for measuring friction torque.
3. Do not interchange the inner and outer races of the same size bearings.
4. Always replace taper roller bearings which are mounted on a shaft together as a set and use bearings from a single manufacturer.

SHIMS

1. Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
2. Check for signs of burr and damage. Install only shims which are in perfect condition.

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

1. Pay attention to the rules of cleanliness when working on the automatic transmission. See «Rules Of Cleanliness For Working On Automatic Transmissions»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01v__rules-of-cleanliness-for-working-on) .
2. Repair instructions. See «GENERAL REPAIR INSTRUCTIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01v__general-repair-instructions) .
3. Apply a thin coat of ATF to the seals. Other lubricants result in operating problems of the hydraulic transmission controls.

Scheme 297

TORQUE CONVERTER, IDENTIFICATION

Different torque converters exist. Identify by the code (arrow). (Scheme 298)

Scheme 298

Allocation torque converter/transmission. See CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT .

TORQUE CONVERTER, CHECKING

Examine hub -arrow- of torque converter for traces of wear. (Scheme 299)

Scheme 299

Note. The torque converter is welded and must be replaced complete if damaged or faulty.

Special Tools & Equipment

1. VAG1358A
2. VAG1358A/1

Scheme 300

Torque Converter Draining

If the ATF is soiled due to shavings or during fundamental reconditioning of the transmission, the torque converter must be emptied

Siphon ATF from torque converter using VAG1358A and VAG1358A/1. (Scheme 301)

Scheme 301

1. VW 681 extractor lever
2. 3295 thrust piece

Scheme 302

Removing

Remove transmission.

Attach transmission to repair stand, or place on a flat surface.

Insert extractor lever VW 681 directly behind the sealing lip of seal, so that the contact ring which is directly behind it is not damaged. (Scheme 303)

Scheme 303

Installing

Install contact ring.

Coat outer circumference and sealing lips of oil seal with ATF.

1. Installation position: Open side of oil seal points toward transmission.

Use thrust piece 3295 to install seal for torque converter as far as stop of thrust piece. (Scheme 304)

Scheme 304

1. Depth caliper gauge

Push torque converter hub through seal onto transmission shaft as far as first stop.

Press torque converter by hand into torque converter bell while rotating it until the recess of torque converter hub engages in pump gear shaft and torque converter is felt to slip into place.

Installation Dimension

If the torque converter is correctly installed, the distance between the faces of the threaded hole at the torque converter and the contact face of the torque converter bell is about 23 mm (29/32 in.). (Scheme 305)

Scheme 305

If the torque converter is not fully installed, this distance is about 11 mm (7/16 in.).

Scheme 306

Scheme 307

Scheme 308

Rules Of Cleanliness For Working On Automatic Transmissions

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover. Use foils and paper. Use lint-free cloths only!
3. Carefully cover over opened components or seal, if repairs are not carried out immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation.
5. Always replace O-rings, gaskets and sealing rings.
6. Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
7. Use only ATF in areas near ATF. Other lubricating substances cause hydraulic transmission control functional problems.
8. Check the following fluid levels after installing, top off if necessary. ATF in planet gear, gear oil in front final drive, transmission fluid in transfer case, and Capacities and specifications. See «SERVICING - A/T (01V WITH 2.7L & 2.8L)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v) article.

AUTOMATIC TRANSMISSION, OVERHAUL

Note. Complete automatic transmission overhaul procedures are not available from the manufacturer.

Removal & Installation

Note. A differentiation is made between two types of transmissions. Transmission with hydraulic control E17, on which the sensor for transmission RPM (inductive sensor) is secured to the underside of the valve body. (Scheme 309) Transmission with hydraulic control E18/2, on which the sensor for transmission RPM (hall sensor is secured behind the valve body on transmission housing. (Scheme 310)

Note. Valve body application can also be determined using code tables. See CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT .

Note. Always replace soiled or faulty valve body.

If transmission is installed in vehicle, raise and support vehicle. Remove noise insulation panel (arrows). (Scheme 311)

Scheme 309

Place drip tray underneath transmission. Remove ATF drain plug (1) and drain ATF. Remove oil pan bolts diagonally in stages Remove oil strainer bolts (arrows). (Scheme 312)

Scheme 310

Pull oil strainer off valve body. Remove wiring harness connector securing clip (arrow). (Scheme 313)

Scheme 311

On vehicles equipped with hydraulic control E17, disconnect transmission vehicle speed sensor (G38) harness connector (arrow). (Scheme 314) On vehicles equipped with hydraulic control E18/2), disconnect transmission vehicle speed sensor harness connector (A) and transmission RPM (G182) (B). (Scheme 315)

Scheme 312

Scheme 313

Note. Only loosen indicated bolts (arrows). If other bolts are loosened, operation of valve body may be affected or separated. (Scheme 316) Bolt (A) is shorter than other bolts. Note location.

On all vehicles, remove valve body securing bolts (arrows). (Scheme 316) While guiding wiring harness connector, remove valve body.

Scheme 314

To install, lightly coat wiring harness connector "O" ring with ATF. Insert wiring harness connector into transmission housing ensuring flat part of rear shoulder points downward, and tabs at shoulder are horizontal.

On vehicles equipped with hydraulic control (E18/2), route wire with connector (C) so that wiring is not pinched during installation of valve body. (Scheme 317)

Scheme 315

On all vehicles, place valve body in position, without force, until detent plate (1) engages in selector lever slide groove (2). (Scheme 318) Tighten valve body bolts starting from inner working outward.

Scheme 316

On vehicles equipped with hydraulic control (E18/2), pull wire with transmission RPM (G182) sensor connector between valve body and wiring harness upward. Connect connector (B) at wiring harness. (Scheme 315) Connect connector (A) to transmission vehicle speed sensor (G38).

On vehicle equipped with hydraulic control E17, connect harness connector (arrow) to transmission vehicle speed sensor (G38). (Scheme 314)

On all vehicles, install securing clip onto wiring harness connector (arrow). (Scheme 313) Lightly coat oil strainer suction shoulder with ATF. Apply thin coat of petroleum jelly to gasket on suction shoulder of oil strainer. Bolt on oil strainer.

Clean all oil pan magnets in beads. Check for full contact of magnets on oil pan. Install NEW gaskets. Install oil pan bolts diagonally in stages. Install ATF according to specifications. See SERVICING - A/T (01V WITH 2.7L & 2.8L) article.

Install noise insulation panel. (Scheme 311)

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 319)

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

Scheme 317

Removing & Installing Rear Final Drive

Remove heat shields from final drive (arrows). (Scheme 320) Disconnect left and right drive axles and rest them on suspension links.

Scheme 318

Place VAG 1383A engine/transmission hoist with 1359/2 transmission support under final drive and support final drive. (Scheme 321)

Scheme 319

Remove securing bolts (arrows) of left final drive support. (Scheme 322) Slide bolts through the bonded rubber bushings of rear crossmember.

Scheme 320

Remove socket head bolts (arrows) at rear of subframe. (Scheme 323) Lower rear final drive.

Scheme 321

Installation is reverse of removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS (REAR FINAL DRIVE) .

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 319)

Top off transmission fluid in rear final drive and check oil level. See SERVICING - A/T (01V WITH 2.7L & 2.8L) article.

Install exhaust system free of stress.

TORQUE SPECIFICATIONS (REAR FINAL DRIVE)

Scheme 322

1. VAG 1306 Drip tray

Scheme 323

Scheme 324

Scheme 325

Removing (Differential)

1. Rear final drive removed. See «REAR FINAL DRIVE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#overhaul-01v) .

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 325)

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.

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.

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

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 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Check adjustment shims for damage after removing.

Scheme 331

Scheme 332

Pressing On Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, place on and then press on. (Scheme 335)

Scheme 333

Pulling Off Double Tapered Roller Bearing Inner Race

Before installing, set 40-105 thrust piece onto differential housing. (Scheme 336)

Scheme 334

Pressing On Double Tapered Roller Bearing Inner Race

Heat inner race to approx. 100° C, place on and then press on. (Scheme 337)

Scheme 335

Scheme 336

Check adjustment shims for damage after removing.

Scheme 337

Scheme 338

Installing Ring Gear

Guide ring gear with centering pins -A- (local manufacturer) when installing ring gear. (Scheme 341)

Scheme 339

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 342)

Scheme 340

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 343)

Scheme 341

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 344)

Scheme 342

Note. The adjustment is also correct when no more play is present and the differential bevel gears can just barely be rotated (arrow). (Scheme 345)

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 343

Removing Drive Pinion Nut

Thread in two hex head bolts M8 x 30 -A-. (Scheme 347)

Scheme 344

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 348)

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

Check adjustment shims for damage after removing.

Scheme 350

Pressing Large Tapered Roller Bearing Inner Race Onto Drive Pinion

Heat inner race to approx. 100° C, place on and then press on. (Scheme 354)

Scheme 351

Pressing In Double Tapered Roller Bearing Outer Race

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

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

Scheme 352

Pressing In Tapered Roller Bearing Outer Race

Install oiled outer race and using VW408A punch and 30-205 thrust pad. (Scheme 356)

Scheme 353

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 357)

Scheme 354

Replacing O-Ring

Insert O-ring with gear oil. (Scheme 358)

Scheme 355

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 359)

Scheme 356

Installing Flange

Drive flange for drive shaft far enough onto drive pinion so that securing nut can be installed. (Scheme 360)

Scheme 357

Tightening Drive Pinion Nut And Adjusting Friction Torque

Thread in two hex head bolts M8 x 30 -A-. (Scheme 347)

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 361)

Scheme 358

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

Adjust to following friction torque. (Scheme 362)

Scheme 359

Securing Drive Pinion Nut

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

Scheme 360

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 361

1. Attach VW387 dial gauge holder with dial indicator to connection between crossmember and final drive. (Scheme 364) 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 362

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 363

Scheme 364

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-01v__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-01v) .
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 355)

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 356)

Install drive pinion without spacer sleeve. Heat tapered roller bearing inner race to 100° C and install on drive pinion. (Scheme 357)

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

Bolt in 3028 retainer using two hex bolts M8 x 30 -A-. (Scheme 347)

Tighten drive pinion nut to achieve following friction torque. (Scheme 362)

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 368) Dimension a = 60 mm

Scheme 365

Adjust sliding adjustment ring. Dimension b = 55 mm. (Scheme 368)

Complete measuring bar as shown in illustration. (Scheme 369) VW385/15 extension pin 9 mm.

Scheme 366

VW385/30 master gauge, adjusting. 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 370)

Scheme 367

Remove master gauge and insert measuring mandrel into housing. (Scheme 371)

Scheme 368

1. VW385/3 plastic piece faces final drive cover

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. (Scheme 371)

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 372)

Scheme 369

Note. Measured value in the following example: "e" = 1.60 mm.

Note. 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 370

Scheme 371

Determine shim as closely as possible according to table. (Scheme 375)

Scheme 372

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 347)

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 371)

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. VW 382/10 extension pin 6mm
2. VW 385/17 magnetic plate
3. VW 387 dial gauge holder
4. VW 388 measuring lever
5. VW 521/4 locking sleeve
6. VW 521/8 bushing
7. Dial gauge
8. Torque wrench 0 - 600 Ncm

Note. 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 ". 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 DIFFERENTIAL, DISASSEMBLING & ASSEMBLING .

Press left tapered roller bearing outer race for differential (housing side) with adjustment shim "S2" into differential housing. See 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 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 376)

Scheme 373

Rotate cover side of differential housing upward.

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

Place VW385/17 magnetic plate onto differential.

Install measuring tools. (Scheme 377) Set dial gauge extension onto center of VW385/17 magnetic plate. Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Scheme 374

Lift differential without turning it, read backlash on dial indicator and note. (Scheme 378)

1. Measured value in the following example: 0.50 mm

Scheme 375

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

Scheme 376

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 377

Calculate adjustment shims as accurately as possible according to the table. see scheme 98

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 381)

Scheme 378

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-01v__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 382)

Scheme 379

Use VW382/10 extension pin, 6 mm. (Scheme 382)

Set VW388 measuring lever to dimension "a" = 60 mm. (Scheme 382)

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 380

Scheme 381

Determine shim as closely as possible according to table. see scheme 96

Scheme 382

Scheme 383

Determine shim as closely as possible according to table. see scheme 98

Scheme 384

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 382)

1. Specification: 0.12 to 0.22 mm

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

See also:
• SERVICING - A/T (01V WITH 2.7L & 2.8L)
• AXLE SHAFTS - FRONT & REAR
• SERVICING - A/T (01L, AWD)
• CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT
• Rules Of Cleanliness For Working On Automatic Transmissions
• GENERAL REPAIR INSTRUCTIONS
• Measuring Driveshaft Radial Runout
• RING GEAR, ADJUSTING
• Removing Drive Pinion Nut
• DRIVE PINION, ADJUSTING