5 Spd. Manual Transmission - 01a Audi A6 C5

Transmission identification

The manual transmission 01A (all wheel drive) is installed in the Audi A6 1998 as a 5-speed transmission in conjunction with the 6-cylinder engine.

Allocation, see CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES .

Location on transmission

1. Code letters and date of manufacture (arrow -1-)
2. Manual transmission 01A (arrow -2-)
3. Code letters (arrow -3-)

Scheme 1

Manual transmission 01A (arrow -2-)

Scheme 2

Code letters and date of manufacture of transmission (arrow -1-)

Scheme 3

Scheme 4

Additional data are required for production.

Note. The transmission code letters are also stamped on the lower part of the transmission cover and shown on the vehicle data stickers.

Scheme 5

Scheme 6

Rear final drive, identification

Final drive 01R is installed together with manual transmission 01A (all wheel drive).

Allocation, see CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES

Code letters and date of manufacture of rear final drive

Scheme 7

Scheme 8

Note. The code letters of the rear final drive are also included on the vehicle data stickers.

Scheme 9

Transmission layout

Note. The following list refers to items in (Scheme 10).

1. Engine
2. Clutch
3. Input shaft (main shaft)
4. Front differential
5. Speedometer drive (electronic)
6. Front drive pinion (output shaft)
7. Transmission
8. Hollow shaft
9. Torsen differential
10. Driveshaft
11. Rear drive pinion
12. Rear differential

Scheme 10

Note. The following list refers to items in (Scheme 10).

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

R - Reverse gear

A1 - Front final drive

A2 - Rear final drive

Note. Arrows point in forward direction of travel.

Engine output/brake test and towing/tow starting, notes

Performance test on the roller type test stand

Observe the following if a vehicle with All Wheel Drive is to be driven onto a performance test stand

1. A all wheel test stand with four braking rolls must be used.

Brake test on the roller type test stand

Observe the following if a vehicle with All Wheel Drive is to be driven onto a performance test stand

1. A slow rotation brake test stand (max. 5.5 km/h) must be used. No gear may be selected during this step.

Tow starting and towing of vehicles

See TOWING .

Transmission ratio

Transmission ratio = No. of teeth driven gear : No. of teeth driven gear

Ratios Formula

iG = gear ratio ZG2 : ZG1

iA = axle ratio ZA2 : ZA1

iov = overall ratio iG x iA

Example

5th gear Final drive

Drive gear ZG1 = 38 ZA1 = 9

Driven gear ZG2 = 30 ZA2 = 35

Calculating

iG = 30 : 38 = 0.789

iA = 35 : 9 = 3.889

iov = (30 : 38) x (35 : 9) = 0.789 x 3.889 = 3.070

Calculating speed "V"

V = n : iov x UA x 0.06

n = Engine speed (rpm)

iov = Overall ratio

UA = Dynamic rolling circumference of tyres (m)

V = Road speed (km/h)

Example

V = 1000:3.100 x 1.93 x 0.06 = 37 km/h

The road speed at an engine speed of 1000 rpm in 5th gear is 37 km/h.

Repair instructions, general

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the repair information, are summarized here.

1. When exchanging the manual transmission or rear final drive, check oil level and top-up if necessary. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level) and «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .
2. Capacities and specifications: See «CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) (transmission) and «CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) (rear final drive).
3. Thoroughly clean all connections and the surrounding area before disconnecting.
4. When installing transmission, ensure dowel sleeves are correctly seated.

Scheme 11

1. Always replace O-rings, seals and gaskets.
2. After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
3. Thoroughly clean housing joint surfaces before assembling.
4. Before installing radial shaft oil seals, lightly oil outer edge and fill space between sealing lips -arrow- with grease.
5. The open side of the oil seals faces toward the side with fluid filling.
6. When replacing oil seal, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
7. Lightly oil O-rings before installing; this prevents the rings being crushed when inserting.
8. Check oil level after replacing gaskets and seals. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .

Sealants

1. Thoroughly clean housing joint surfaces before applying sealing paste.
2. Apply sealing paste AMV 188 200 03 or AMV 188 001 02 evenly and not too thick. Do not use sealing paste AMV 188 001 02 on a transmission with magnesium housing.
3. Breather holes must remain free of sealing paste.

Locking elements

1. Do not overstretch circlips.
2. Always replace damaged or overstreched circlips.
3. Circlips must locate properly in the groove.
4. Replace spring pins. Position: the slit in the pin should be in line with the line of force. (Scheme 12)

Scheme 12

Nuts, bolts

1. Loosen nuts or bolts, opposite to tightening sequence.
2. Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
3. Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
4. The tightening torques stated apply to non-oiled nuts and bolts.
5. Replace self-locking bolts and nuts.
6. The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 A1 when inserting.
7. Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Bearings

1. Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift or other tool used for installing.
2. Remove and tighten bolts/nuts for securing covers and housings in a diagonal sequence.
3. Grease needle bearing for transmission input shaft in rear of flywheel.
4. Lubricate all bearings in transmission housing with gear oil before installing.
5. Heat inner races of taper roller bearings to approx. 100 °C before installing. Press in onto stop when installing so there is no axial clearance.
6. Do not interchange the outer and inner races of bearings of the same size.
7. Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
8. The taper roller bearings for the output shaft and the differential in the transmission are low-friction bearings. Do not additionally oil new taper roller bearings when measuring friction torque. The bearings are pre-treated at the factory with a special type of oil for this purpose.

Shims

1. Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain the exact shim thickness required.
2. Check for burrs and damage.
3. Only install perfect, undamaged shims.

Gears, synchro-hubs, inner races for sliding gears

1. Heat gears and synchro-hubs to approx. 100 °C before installing. Press in onto stop when installing so there is no axial clearance.
2. Heat inner races for sliding gears to approx. 100 °C when installing.
3. The temperature can be checked with Temperature tester V.A.G 1558.
4. Observe installation position.

Sliding gears

1. After assembling, check axial clearance of 1st to 5th sliding gears and reverse sliding gear (0.15-0.35 mm) and check for freedom of movement.

Synchronizer rings

1. Do not interchange synchronizer rings. When reusing always fit to the same gear.
2. Check for wear, replace if necessary.
3. Lubricate with gear oil before installing.

Clutch mechanism

1. When removing transmission, remove clutch slave cylinder without disconnecting pipes.
2. Do not depress clutch pedal after removing slave cylinder. Otherwise the piston will be pressed out of the slave cylinder.
3. Do not cant clutch pressure plate, loosen and tighten in a diagonal sequence and in stages.
4. To reduce odor caused by a burnt clutch, thoroughly clean the clutch bellhousing, the flywheel and the parts of the engine facing the transmission.

Scheme 13

1. Ring spanner 7-piece set 3337

Requirement

1. Transmission installed

Removing

Vehicles with 6-cylinder engine

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Unscrew lambda probe from right exhaust pipe using special tool 3337, and move clear to the side.
2. Remove heat shield above right-hand axle shaft.
3. Unbolt front exhaust pipe with catalytic converter (right side) from exhaust manifold -arrows- (3 nuts): See appropriate Exhaust System article in ENGINES.
4. Remove heat shield for driveshaft from cover for Torsen differential -arrows-.
5. Unbolt driveshaft -1- from transmission and rest it on heat shield -2-. (Scheme 16)
6. Secure driveshaft to fuel pipe bracket -3- with wire -arrow-.
7. Place a drip tray underneath.
8. Drain gear oil.
9. Unbolt cover -A- with Torsen differential from transmission cover -B-. NOTE: Shown in illustration with transmission removed.
10. Remove spring -C- from drive pinion.

Installing

Installation is carried out in the reverse order, when doing this note the following

Scheme 18

1. Check that dowel sleeves for cover -A- are fitted in transmission cover -B- (arrows).
2. Lightly coat sealing surfaces with AMV 188 001 02 sealant.
3. Bolt on driveshaft. See «INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
4. Top up transmission oil and check oil level in transmission. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level) .

Tightening torque

TORQUE SPECIFICATIONS: COVER WITH TORSEN DIFFERENTIAL

Transmission, disassembling and assembling

For sequence, see INPUT SHAFT BALL BEARING, MULTI-FUNCTION SENDER, INPUT SHAFT, DRIVE PINION, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING .

Transmission overview

Note. The following list refers to items in (Scheme 19).

1. 1st gear
2. 2nd gear
3. 3rd gear
4. 4th gear
5. 5th gear
6. Reverse gear Removing and installing reverse idler gear, see «REVERSE GEAR WHEEL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__reverse-gear-wheel-removing-and-installing)
7. Taper roller bearing Adjusting, see «DRIVE PINION, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__drive-pinion-adjusting)
8. Torsen differential Can only be serviced by manufacturer Removing and installing with cover, see «COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
9. Bearing
10. Bearing
11. Drive flange
12. Cover for Torsen differential
13. Spring Between Torsen differential and hollow shaft
14. Input shaft Disassembling and assembling, see «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
15. Transmission cover
16. Transmission housing
17. Bearing Adjusting thickness adjusting input shaft, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
18. Differential Removing and installing, see «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-removing-and-installing) Disassembling and assembling, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-disassembling-and-assembling)
19. Drive pinion Disassembling and assembling hollow shaft and drive pinion, see «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
20. Radial taper roller bearing Adjusting, see «DRIVE PINION, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__drive-pinion-adjusting)
21. Hollow shaft Disassembling and assembling hollow shaft and drive pinion, see «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)

Scheme 19

Scheme 20

1. Removing and installing input shaft ball bearing and multi-function sender, see «INPUT SHAFT BALL BEARING AND MULTI-FUNCTION SENDER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-ball-bearing-and-multi-function)
2. Removing and installing input shaft, drive pinion, hollow shaft, selector rods, transmission cover and cover with Torsen differential, see «INPUT SHAFT, DRIVE PINION, HOLLOW SHAFT, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-drive-pinion-hollow-shaft)

Input shaft ball bearing and multi-function sender, removing and installing

Note. The following list refers to items in (Scheme 21).

1. Transmission housing With differential and drive flanges Removing and installing differential and drive flanges, see «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-removing-and-installing) Removing and installing speedometer sender and drive wheel, see «SPEEDOMETER SENDER AND DRIVE WHEEL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__speedometer-sender-and-drive-wheel-removing) . See «Breather installation position»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__breather-installation-position) .
2. Torx socket head bolt, 35 Nm Self-locking Replace
3. Guide sleeve With O-ring and oil seal for input shaft: See «CLUTCHES - O1A, AWD»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) .
4. Dished washer Smaller diameter (convex side) faces guide sleeve
5. Circlip Determining thickness adjusting input shaft, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
6. Bearing Removing and installing, see «INPUT SHAFT BALL BEARING, MULTI-FUNCTION SENDER, INPUT SHAFT, DRIVE PINION, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-ball-bearing-multi-function-sender)
7. Circlip Determining thickness adjusting input shaft, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
8. Input shaft Removing and installing, see «INPUT SHAFT, DRIVE PINION, HOLLOW SHAFT, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-drive-pinion-hollow-shaft) Disassembling and assembling, see «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Adjusting, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting) Servicing input shaft bearings, see «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
9. Bolt, 25 Nm
10. Locking plate For multi-function sender
11. Multi-function sender
12. Multi-function sender connector
13. Bolt, 10 Nm
14. Cover for selector shaft Removing and installing, see «TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__transmission-selector-mechanism-disassembling-and-assembling)
15. Locking unit for 5th gear and reverse gear Removing and installing, see «REMOVING AND INSTALLING LOCKING UNIT FOR 5TH GEAR AND REVERSE GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)

Scheme 21

Breather installation position

After pressing in, the breather must project 21 mm out of housing.

Scheme 22

Input shaft, drive pinion, hollow shaft, selector rods, transmission cover and cover with Torsen differential, removing and installing

Note. The following list refers to items in (Scheme 23).

1. Transmission housing Lightly coat sealing surfaces with AMV 188 001 02 sealant
2. Input shaft Disassembling and assembling, see «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Adjusting, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting) Servicing input shaft bearings, see «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
3. Selector rod with selector fork for 3rd and 4th gear Disassembling and assembling, see «TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__transmission-selector-mechanism-disassembling-and-assembling) Replacing mounting bushes, see «TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__transmission-selector-mechanism-disassembling-and-assembling)
4. Left stop bolt, 40 Nm
5. Oil seal
6. Relay shaft Installation position, see INSTALLATION POSITION
7. Oil seal
8. Right stop screw, 40 Nm
9. Selector shaft Installation position, see INSTALLATION POSITION Replacing selector shaft oil seal, see «OIL SEAL INSTALLATION POSITION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-seal-installation-position)
10. Detent segment Installation position, see «INSTALLATION POSITION OF 5TH AND REVERSE GEAR SELECTOR FORK AND COUPLING PLATE FOR SELECTOR ROD»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-5th-and-reverse)
11. Torx bolt, 25 Nm With shoulder to secure the detent segment spring
12. Selector rod with 1st/2nd/5th and reverse gear selector forks Disassembling and assembling, see «TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__transmission-selector-mechanism-disassembling-and-assembling) Removing and installing ball sleeves, see «REMOVING AND INSTALLING BALL SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
13. Drive pinion with hollow shaft Disassembling and assembling, see «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Adjusting, see «DRIVE PINION AND RING GEAR, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__drive-pinion-and-ring-gear-adjusting) Servicing drive pinion and hollow shaft bearings, see «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
14. Transmission cover Removing and installing oil collector tray, see «REMOVING AND INSTALLING OIL COLLECTOR TRAY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Lightly coat sealing surfaces with AMV 188 001 02 sealant
15. Torx bolt, 22 Nm
16. Spring
17. Cover with Torsen differential Removing and installing with transmission installed, see «COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Removing and installing Torsen differential from cover, see «TORSEN DIFFERENTIAL, SERVICING COVER AND REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__torsen-differential-servicing-cover-and-removing) Servicing cover, see «TORSEN DIFFERENTIAL, SERVICING COVER AND REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__torsen-differential-servicing-cover-and-removing) Lightly coat sealing surfaces with AMV 188 001 02 sealant
18. Torx bolt, 22 Nm

Scheme 23

1. Turn the oil collector tray -arrow- and then pull out.

Scheme 24

1. Push oil collector tray into the transmission, until it snaps in.

Position: oil collector tray faces upward in transmission cover

Input shaft ball bearing, multi-function sender, input shaft, drive pinion, selector rods, transmission cover and cover with Torsen differential, removing and installing

Note. To remove the above-mentioned components it is not necessary to remove the differential. Removal is only necessary when adjustments have to be carried out. See ADJUSTMENT OVERVIEW .

Special tools, testers and auxiliary items

1. Socket 3357
2. Retaining plate VW 309
3. Transmission support VW 353
4. Removal tool V. A. G. 1582
5. Clamping piece V. A. G. 1582/2
6. Pressing-in tool 3235
7. Collector tray VAG1306
8. 188 200 03 or AMV 188 001 02

Scheme 25

Scheme 26

1. Place a drip tray underneath.
2. Drain gear oil.
3. Secure transmission in assembly stand VW 540.
4. Remove clutch release lever -A- with release bearing.

Note. Before pulling off guide sleeve, cover splines on input shaft with a shrink-fit hose to protect oil seal. Removing oil seal in guide sleeve, see CLUTCHES - O1A, AWD

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

1. Remove guide sleeve -B-.
2. Remove dished washer -C-.
3. Remove circlip -D- in front of input shaft ball bearing.
4. If the ball bearing, input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
5. Pull the input shaft ball bearing out of transmission housing.
6. Remove the circlip (arrow) behind the input shaft ball bearing.
7. If the ball bearing, input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
8. Unbolt cover -A- with Torsen differential from transmission cover -B-.
9. Remove spring from drive pinion.
10. Then unbolt transmission cover -B- from transmission housing -C-.
11. Remove bolts (arrows) and pull out the multi-function sender.
12. Remove relay shaft bolts (arrows).
13. Unbolt the detent segment (arrow) and swing it out.
14. The input shaft -A-, the drive pinion -B-, the relay shaft -C-, the selector rods -D- with selector shaft and the selector forks -E- must be carefully pulled out together.

Note. If the input shaft ball bearing, the input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of the circlips for the input shaft. See INPUT SHAFT, ADJUSTING .

Scheme 34

Scheme 35

1. Swing the transmission housing into the position shown.
2. It is then easier to install the following mentioned components.
3. Assemble the input shaft -A-, the drive pinion -B-, the relay shaft -C-, the selector rods -D- with selector shaft and selector forks -E- together.
4. Install these components together into the transmission housing.

Note. The relay shaft -C- and the selector shaft can also be installed later if necessary.

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. Turn transmission housing and engage 3rd gear (direction of arrow).
2. Now install relay shaft -A-. (Scheme 37)
3. Insert selector shaft -B- sideways onto the drilling in transmission housing and assemble into mounting eye.
4. Then turn the selector shaft carefully in direction of arrow.
5. Then insert the detent segment and bolt it tight (arrow).
6. Now insert the relay shaft bolts (arrows).
7. Replace O-ring for multi-function sender.
8. Carefully insert multi-function sender and tighten (arrows).
9. Check that dowel sleeves for transmission cover -A- are fitted in transmission housing -B-(arrows). (Scheme 41)
10. Lightly coat sealing surfaces with AMV 188 001 02.
11. Fit transmission cover onto transmission housing.
12. Check that dowel sleeves for cover -A- are fitted in transmission cover -B-(arrows). (Scheme 42)
13. Fit spring -C-.
14. Fit cover with Torsen differential -A- on transmission cover -B-.
15. Fit rear input shaft ball bearing circlip (arrow). (Scheme 43)
16. Slide the ball bearing onto the input shaft. Position: closed side of ball cage faces toward transmission housing
17. Press in ball bearing. (Scheme 44)
18. Slide thrust piece -A- of pressing-in tool onto input shaft.
19. Position pressing-in tool behind splines for clutch plate.
20. Screw in bolts -B- until they make contact. The bolts bear against the indentations in thrust piece -A-. (Scheme 44)
21. Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).
22. Now fit the input shaft ball race front circlip -D-. (Scheme 45)
23. Then fit dished washer -C-. Position: convex side toward guide sleeve -B

Note. Before fitting guide sleeve, cover splines on input shaft with a shrink-fit hose to protect oil seal. Installing oil seal in guide sleeve, see CLUTCH MECHANISM, SERVICING

Scheme 45

1. Fit guide sleeve -B- for release bearing.
2. Fit clutch release lever -A- and release bearing.

Torsen differential, servicing cover and removing and installing

Special tools and equipment

1. VW401 thrust plate and VW402 thrust plate
2. VW407 punch
3. VW412 punch
4. VW416B tube
5. VW 421 sleeve
6. VW439 guide pin
7. VW 519 sleeve
8. VW681 extractor lever
9. VW771/15 from VW771 slide hammer-complete set
10. Sleeve 40-21
11. Tube 2040
12. Thrust piece 3002
13. Kukko 17/2 separating tool
14. Kukko 21/1 extractor

Note. The following list refers to items in (Scheme 47).

1. Transmission cover
2. Spring
3. Front needle bearing Removing, see «PULLING OUT NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-needle-bearing) Installation position, see «INSTALLATION POSITION OF FRONT NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Pressing in, see «PRESSING IN NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-needle-bearing)
4. Torsen differential Do not dismantle Press out after removing drive flange. See «PRESSING OUT TORSEN DIFFERENTIAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-out-torsen-differential) . Replace if damaged Pressing in, see «PRESSING IN TORSEN DIFFERENTIAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
5. Rear needle bearing Removing, see «PULLING OUT NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-needle-bearing) Installation position, see «INSTALLATION POSITION OF REAR NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-rear-needle-bearing) Pressing in, see «PRESSING IN NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-needle-bearing)
6. Ball bearing For Torsen differential Pressing off, see «PRESSING OFF BALL BEARING FROM TORSEN DIFFERENTIAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-ball-bearing-from-torsen) Pressing on, see «PRESSING BALL BEARING ONTO TORSEN DIFFERENTIAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-ball-bearing-onto-torsen-differential)
7. Circlip
8. Circlip Remove and install together with drive flange. See «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-and-installing-drive-flange) .
9. Bearing For drive flange Pressing off, see «PRESSING OUT BALL BEARING FOR DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-out-ball-bearing-for-drive) Pressing in, see «PRESSING IN BALL BEARING FOR DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-ball-bearing-for-drive)
10. Cover For Torsen differential Lightly coat sealing surfaces with AMV 188 001 02
11. Circlip
12. Plug Removing, see «REMOVING PLUG»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-plug)
13. O-ring Replace Grease when installing
14. Torx bolt, 25 Nm
15. Oil seal Pull out with oil seal extractor lever VW 681 Knocking in, see «DRIVING IN SEAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driving-in-seal)
16. Vibration damper
17. Circlip
18. Torx bolt, 35 Nm Self-locking Replace
19. Drive flange Removing and installing, see «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-and-installing-drive-flange)

Scheme 46

Removing plug

1. Remove circlip -A-.
2. Screw an M8 bolt into thread of plug -B-.
3. Pull out plug -B- using bolt.

Scheme 47

Removing and installing drive flange

1. Open out circlip and pull out drive flange
2. When inserting drive flange, fit circlip at the same time. The circlip must be seated in the base of the groove.

Scheme 48

Pressing out Torsen differential

1. Position thrust piece 3002 directly on Torsen differential through opening (arrow).

Scheme 49

Pressing off ball bearing from Torsen differential

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 50

Pressing ball bearing onto Torsen differential

1. Press ball bearing on as far as the stop.

Scheme 51

Pressing out ball bearing for drive flange

1. Remove circlip before pressing out bearing.

Scheme 52

Pressing in ball bearing for drive flange

1. Fit circlip after pressing in bearing.

Scheme 53

Pulling out needle bearing

A - Internal puller 22-28 mm, e.g. Kukko 21/4

1. Both needle bearings in the Torsen differential are removed with the same puller.

Scheme 54

Scheme 55

1. Distance a = 32.5 mm

Installation position of rear needle bearing

1. Distance a = 14 mm

Scheme 56

Pressing in needle bearing

1. Both needle bearings in the Torsen differential are pressed in with the same special tool.

Scheme 57

Scheme 58

Driving in seal

1. Fill space between sealing lip and dust lip with multi-purpose grease.
2. Lightly oil outer circumference of seal. Position: 2 mm below surface of cover

Scheme 59

Transmission selector mechanism, disassembling and assembling

Special tools and equipment

1. VW295 needle bearing drift
2. VW295A needle-bearing drift
3. VW401 thrust plate
4. VW 423 sleeve
5. VW472/2 spacer sleeve
6. VW771 slide hammer - complete set
7. Kukko 21/1 extractor

Note. For installation position of the complete selector mechanism in transmission (Scheme 67)(Scheme 67)

Note. The following list refers to items in (Scheme 61).

1. Locking unit for 5th gear and reverse gear Removing and installing, see «REMOVING AND INSTALLING LOCKING UNIT FOR 5TH GEAR AND REVERSE GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
2. Torx bolt, 10 Nm
3. O-ring Replace
4. Right stop bolt, 40 Nm
5. Oil seal
6. Relay shaft
7. Oil seal
8. Left stop bolt, 40 Nm
9. Detent segment
10. Torx bolt, 25 Nm
11. Spring pin
12. 5th and reverse gear selector fork Installation position, see «INSTALLATION POSITION OF 5TH AND REVERSE GEAR SELECTOR FORK AND COUPLING PLATE FOR SELECTOR ROD»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-5th-and-reverse)
13. Selector rod for 1st and 2nd gear as well as for 5th and reverse gear
14. Ball sleeve Removing and installing, see «REMOVING AND INSTALLING BALL SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
15. Selector fork for 1st and 2nd gear
16. Coupling plate Installation position, see «INSTALLATION POSITION OF 5TH AND REVERSE GEAR SELECTOR FORK AND COUPLING PLATE FOR SELECTOR ROD»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-5th-and-reverse)
17. Bush Removing, see «PULLING OUT MOUNTING BUSH FOR 3RD AND 4TH GEAR SELECTOR ROD»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-mounting-bush-for-3rd) Installing, see «DRIVING IN 3RD AND 4TH GEAR SELECTOR ROD MOUNTING BUSH ONTO STOP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
18. Ball sleeve Lever off the selector rod with a screwdriver Press onto the selector rod
19. Selector rod for 3rd and 4th gear
20. Selector fork for 3rd and 4th gear
21. Spring pin
22. Cover For selector shaft
23. Torx bolt, 20 Nm
24. Selector shaft
25. Oil seal Lever out with screwdriver Installation position, see «OIL SEAL INSTALLATION POSITION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-seal-installation-position)

Scheme 60

Installation position of 5th and reverse gear selector fork and coupling plate for selector rod

1. Distance -a- = 55 mm
2. Distance -b- = 60 mm

Scheme 61

Scheme 62

Pulling out mounting bush for 3rd and 4th gear selector rod

A - Internal puller 22-28 mm, e.g. Kukko 21/4, in conjunction with multi-purpose tool VW 771

Scheme 63

Scheme 64

Oil seal installation position

1. Fill space between sealing and dust lips with multi-purpose grease.
2. Lightly oil outer circumference of seal. Distance -a- = 1 mm

Scheme 65

Installation position of complete selector mechanism in transmission

1. Selector fork for 5th gear and reverse gear
2. Selector fork for 3rd gear and 4th gear
3. Selector fork for 1st gear and 2nd gear
4. Relay shaft
5. Detent mechanism
6. Selector shaft

Scheme 66

Scheme 67

Scheme 68

1. Remove heat shield -arrow -2- above right axle shaft.
2. Detach heat shield -arrow -1- above right axle shaft and pivot downward.
3. Remove locking unit -arrow-.

Scheme 69

1. Insert spring -1- into housing -2- and, while exerting light pressure, turn spring to the left until it locates in the base of the housing. (Scheme 70)
2. Insert bush -3- onto the spring so that the bent end of the spring locates in the groove.
3. Push bush against spring and turn approx. one turn to left, until the lug on the bush aligns with the groove in the housing.
4. Press lug on bush onto stop in the groove in the housing.
5. Turn bush to right and release. The bush will jump into the correct position.

Installation position of bush.

1. The lug (arrow -A-) on the bush must always be opposite the groove in the housing (arrow -B-). (Scheme 71)

Scheme 70

Checking installation position

1. Turn bush to left and release. The bush should spring back into position; the lug must be against the stop (direction indicated by arrow -A-).

Installation position of complete locking unit in transmission

The recess (arrow -A-) faces bolt (arrow -B-).

Scheme 71

Special tools and equipment

1. VW222A pilot drift
2. VW295 needle bearing drift
3. VW295A needle-bearing drift
4. VW401 thrust plate and VW402 thrust plate
5. VW407 punch and VW408A punch
6. VW415A tube and VW416B tube
7. VW447I thrust pad
8. VW771 slide hammer - complete set
9. 30-24 Drift
10. 30-100 Press tube
11. 40-105 Thrust piece
12. 40-202 Press out piece
13. Kukko 17/2 separating tool
14. Kukko 21/1 extractor

Note. When installing the input shaft or new gears, consult technical data. See CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES . If parts are exchanged which will affect the position of the ball bearings, the input shaft must be re-adjusted. See INPUT SHAFT, ADJUSTING .

Note. The following list refers to items in (Scheme 73).

1. Circlip Identification color Installation position (Scheme 85), item -1- Determining thickness adjusting input shaft, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
2. Ball bearing Removing and installing, see «INPUT SHAFT BALL BEARING, MULTI-FUNCTION SENDER, INPUT SHAFT, DRIVE PINION, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-ball-bearing-multi-function-sender)
3. Circlip Identification color Installation position (Scheme 85), item -2- Determining thickness adjusting input shaft, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
4. Transmission housing
5. Needle roller bearing Secured with bolt, see «SECURING BOLT FOR NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__securing-bolt-for-needle-bearing) Removing, see «DRIVING-OUT NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Installation position, see «INSTALLATION POSITION OF NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-needle-bearing) Pressing in, see «PRESSING IN NEEDLE BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
6. Input shaft With oiling sleeve Knocking in oiling sleeve, see «DRIVING IN OILING SLEEVE INTO INPUT SHAFT»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driving-in-oiling-sleeve-into-input) Adjusting, see «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting)
7. Needle bearing for 3rd gear
8. 3rd speed sliding gear
9. Spring Insert in 3rd speed sliding gear, see «INSERTING SPRING IN 4TH SPEED SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
10. Synchro-ring for 3rd gear Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__checking-synchro-ring-for-wear)
11. Circlip Identification color Installation position (Scheme 85), item -3
12. Synchro-hub for 3rd and 4th gear Shoulder faces to 3rd gear Pressing off, see «PRESSING OFF SYNCHRO-HUB FOR 3RD AND 4TH GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-synchro-hub-for-3rd-and) Pressing on, see «PRESSING ON SYNCHRO-HUB FOR 3RD AND 4TH GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
13. Circlip Identification color Installation position (Scheme 85), item 4 If the synchro hub is replaced, re-determine thickness. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-thickness-of-circlip).
14. 3rd and 4th gear locking collar Installation position, see «INSTALLATION POSITION OF LOCKING COLLAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-locking-collar)
15. Synchro-ring for 4th gear Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__checking-synchro-ring-for-wear)
16. Spring Insert in 4th speed sliding gear. See «INSERTING SPRING IN 4TH SPEED SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
17. 4th speed sliding gear
18. Needle roller bearing For 4th gear
19. 5th gear wheel Pressing off, see «PRESSING OFF 5TH GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-5th-gear-wheel) Pressing on, see «PRESSING ON 5TH GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-5th-gear-wheel)
20. Circlip Identification color Installation position (Scheme 85), item -5- If the 5th gear wheel is replaced, re-determine thickness. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-thickness-of-circlip).
21. Roller sleeve Replace Will be damaged when removing Pulling out, see «PULLING OUT ROLLER SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-roller-sleeve) Installation position, see «INSTALLATION POSITION OF ROLLER SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-roller-sleeve) Driving in, see «DRIVING IN ROLLER SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
22. Sleeve Made of plastic
23. Transmission cover

Scheme 72

Securing bolt for needle bearing

1. Unscrew securing bolt -arrow-.

Scheme 73

Scheme 74

Installation position of needle bearing

Dimension "a" from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm

Note. Measure distance from top edge of straight-edge and subtract the width of the straight-edge from the measured distance.

Scheme 75

1. Install securing bolt and tighten to 25 Nm.

Scheme 76

Pulling out roller sleeve

A - Internal puller 22-28 mm, e.g. Kukko 21/4

1. Before fitting internal puller the plastic sleeve inside the roller sleeve must be destroyed.

Scheme 77

Installation position of roller sleeve

1. Distance a = 216 mm

Scheme 78

Scheme 79

Pressing off 5th gear wheel

1. Remove circlip before pressing off.

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 80

Pressing off synchro-hub for 3rd and 4th gear

1. Remove circlip before pressing off.
2. Press 3rd gear synchro ring (arrow) towards 3rd gear wheel, then fit separating device -A-.

Scheme 81

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 82

The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.

Checking synchro-ring for wear

1. Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
2. Calculate average gap.

Scheme 83

The average gap must not be less than 0.5 mm.

Scheme 84

1. The circlips -1- and -2- secure the input shaft ball bearing. (Scheme 85) Determine thickness adjusting input shaft. See «INPUT SHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__input-shaft-adjusting).
2. The circlip -3- secures the 3rd and 4th gear synchro-hub. (Scheme 85) Thickness: 2.00 mm Identification: brown color
3. The circlip -4- secures the 3rd and 4th gear synchro-hub. (Scheme 85) Determine thickness. See «3RD AND 4TH GEAR SYNCHRO-HUB CIRCLIP AVAILABILITY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a). Identification: blue color
4. The circlip -5- secures the 5th gear wheel. Determine thickness. See «5TH GEAR WHEEL CIRCLIP AVAILABILITY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).

Determining thickness of circlip

1. Determine the thickest circlip which will just fit and install it.
2. Determine circlip from table.

Scheme 85

The following circlips are available for synchro-hub for 3rd and 4th gear

3RD AND 4TH GEAR SYNCHRO-HUB CIRCLIP AVAILABILITY

The following circlips are available for 5th gear wheel

5TH GEAR WHEEL CIRCLIP AVAILABILITY

Scheme 86

Installation position of locking collar

Operating sleeves with chamfer -A- as well as operating sleeves with large offset -B- are installed.

Installation position

Scheme 87

1. Chamfer (arrow 1) faces 4th gear
2. Small stepped side (arrow 2) faces 3rd gear
3. Large stepped side (arrow 3) faces 4th gear

Pressing on 5th gear wheel

1. Heat 5th gear wheel to approx. 100 degrees C before pressing on. Position: wider collar faces towards reverse gear

Scheme 88

Driving in oiling sleeve into input shaft

1. Installation position: flared edge of oil sleeve faces installation tool
2. Installation depth: 3.5 mm under below upper edge

Scheme 89

Scheme 90

Input shaft, adjusting

Note. The input shaft must be readjusted if the transmission housing, the input shaft or the ball bearing are replaced.

1. Drive sleeve 30-100
2. Distance gauge 3167
3. Depth gauge

Calculating dimension "x"

1. Clamp input shaft in vice using vice clamps -A-.
2. Place distance gauge 3167 onto 3rd speed sliding gear.
3. Place transmission housing over input shaft onto the distance gauge.

Scheme 91

Scheme 92

1. Place depth gauge onto transmission housing and measure to the lower circlip groove in the input shaft. (Scheme 93) Measurement in the following example: "a" = 28.50 mm
2. Place depth gauge onto transmission housing and measure to seating surface for ball bearing. (Scheme 94) Measurement in the following example: "b" = 26.80 mm

Scheme 93

Determining circlip behind the input shaft ball bearing

Formula

"x" = "a" - "b"

Example

Dimension "a" 28.50 mm

1. Dimension "b" 26.80 mm

= Dimension "x" (thickness of circlip) 1.70 mm

1. Determine circlip from table.

Circlips available

CIRCLIP BEHIND INPUT SHAFT BALL BEARING AVAILABILITY

Scheme 94

1. Knock rear circlip (as calculated) and ball bearing onto the input shaft with fitting sleeve 30-100.
2. Determine the thickest circlip which will still fit.
3. Determine circlip from table.

Circlips available

CIRCLIP IN FRONT OF INPUT SHAFT BALL BEARING AVAILABILITY

1. VW401 thrust plate
2. VW402 thrust plate
3. VW407 punch
4. VW411 Punch
5. VW412 punch
6. VW 415 A tube
7. VW416B tube
8. VW 418 A tube
9. VW 429 thrust ring
10. VW447I thrust pad
11. VW442 thrust pad
12. VW 519 sleeve
13. VW771 slide hammer - complete set
14. Sleeve 40-103
15. Sleeve 2010
16. Thrust pad 3062
17. Bushing puller 3128
18. Kukko 17/2 separating tool
19. Kukko 21/1 extractor

Procedure

Note. When installing new gear wheels or the final drive set consult technical data. See CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES . Adjustments are required when replacing components marked "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in (Scheme 96).

1. Transmission housing
2. Shim "S3" See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__adjustment-overview).
3. Double taper roller bearing outer race 1) Pulling out, see «PULLING OUT DOUBLE TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-double-taper-roller-bearing) Pressing in, see «PRESSING IN DOUBLE TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-double-taper-roller-bearing)
4. Drive pinion 1) Is mated with ring gear, always replace together as a set Adjusting drive pinion and ring gear, see «DRIVE PINION AND RING GEAR, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__drive-pinion-and-ring-gear-adjusting)
5. Double taper roller bearing inner race 1) Pressing off, see «PRESSING OFF DOUBLE TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-double-taper-roller-bearing) Pressing on, see «PRESSING ON DOUBLE TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
6. Circlip Redetermine thickness if double taper roller bearing is replaced. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
7. Needle roller bearing For drive pinion in hollow shaft Lubricate with MoS2 grease
8. Hollow shaft 1)
9. Needle bearing for 1st gear
10. Needle bearing for 1st gear
11. 1st speed sliding gear
12. Spring Insert in 1st speed sliding gear. See «INSERTING SPRING IN SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__inserting-spring-in-sliding-gear).
13. Synchro-ring for 1st gear Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
14. Synchro-hub for 1st and 2nd gear Pressing off, see «PRESSING OFF 1ST AND 2ND GEAR SYNCHRO-HUB»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-1st-and-2nd-gear) Pressing on, see «PRESSING ON 1ST AND 2ND GEAR SYNCHRO-HUB»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-1st-and-2nd-gear)
15. Circlip Identification color Installation position (Scheme 111), item -1- Redetermine thickness if synchro-hub is replaced. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
16. Needle roller bearing For 2nd gear
17. Locking collar for 1st and 2nd gear Installation position, see «INSTALLATION POSITION OF LOCKING COLLAR FOR 1ST AND 2ND GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-locking-collar-for)
18. Synchro-ring for 2nd gear Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
19. Spring Insert in 2nd speed sliding gear. See «INSERTING SPRING IN SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__inserting-spring-in-sliding-gear).
20. 2nd speed sliding gear
21. Circlip Identification color Installation position (Scheme 111), item -2
22. 3rd gear wheel Pressing off, see «PRESSING OFF 3RD GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-3rd-gear-wheel) Pressing on, see «PRESSING ON 3RD GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-3rd-gear-wheel)
23. Circlip Identification color Installation position (Scheme 111), item -3- Redetermine thickness if 3rd gear wheel is replaced. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
24. 4th gear wheel Pressing off, see «PRESSING OFF 4TH GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-4th-gear-wheel) Pressing on, see «PRESSING ON 4TH GEAR WHEEL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-4th-gear-wheel)
25. Circlip Identification color Installation position (Scheme 111), item -4- Redetermine thickness if 4th gear wheel is replaced. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
26. Needle roller bearing
27. 5th speed sliding gear
28. Spring Insert in 5th speed sliding gear. See «INSERTING SPRING IN SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__inserting-spring-in-sliding-gear).
29. Synchro-ring for 5th gear Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
30. Circlip Identification Installation position (Scheme 111), item -5
31. 5th gear synchro-hub Pressing off, see «PRESSING OFF 5TH GEAR AND REVERSE GEAR SYNCHRO-HUB»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-5th-gear-and-reverse) Pressing on, see «PRESSING ON 5TH GEAR AND REVERSE GEAR SYNCHRO-HUB»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-5th-gear-and-reverse)
32. Circlip Identification color Installation position (Scheme 111), item -6- Redetermine thickness if synchro-hub is replaced. See «DETERMINING THICKNESS OF CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a).
33. Needle roller bearing For reverse gear
34. 5th and reverse gear locking collar Installation position, see «INSTALLATION POSITION OF OPERATING SLEEVE FOR 5TH AND REVERSE GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installation-position-of-operating-sleeve-for)
35. Reverse gear synchro-ring Checking for wear, see «CHECKING SYNCHRO-RING FOR WEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
36. Spring Insert in reverse sliding gear. See «INSERTING SPRING IN SLIDING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__inserting-spring-in-sliding-gear).
37. Reverse sliding gear
38. Circlip Identification color Installation position (Scheme 111), item -7
39. Inner race for taper roller bearing 1) Pressing off, see «PRESSING OFF TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-off-taper-roller-bearing-inner) Pressing on, see «PRESSING ON TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-taper-roller-bearing-inner)
40. Bush To secure small taper roller bearing outer race Pulling out, see «PULLING OUT SECURING BUSH FOR TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-securing-bush-for-taper) Need not be fitted after the small taper roller bearing has been replaced
41. Outer race for taper roller bearing 1) Pressing out, see «PRESSING OUT TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-out-taper-roller-bearing-outer) Pressing in, see «PRESSING IN TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
42. Shim "S4" See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__adjustment-overview).
43. Ring Holds rubber washer
44. Rubber washer Compensates length variations
45. Transmission cover

Scheme 95

Pulling out double taper roller bearing outer race

1. Remove differential. See «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-removing-and-installing) .
2. Place pressure piece of puller 3128 below the outer race.
3. Fit threaded part of puller 3128 with pressure plate VW 401 onto transmission housing.

When the bolt is tightened the outer race will be pulled out of the housing.

Scheme 96

Pressing off double taper roller bearing inner race

1. Remove circlip before pressing off.
2. The outer race -A- must be fitted to press off the inner race.

Note. Inner race of double tapered roller bearing is destroyed during removal.

Scheme 97

Pressing in double taper roller bearing outer race

The smaller diameter of the special tool 3062 faces outer race.

Scheme 98

Scheme 99

1. Determine the thickest circlip which will still fit and install it.
2. The circlips for the synchro-hubs, needle bearings and individual gear wheels should be determined as for the double taper roller bearing shown.

Scheme 100

Pulling out securing bush for taper roller bearing outer race

A - Internal puller 12-14.5 mm, e.g. Kukko 21/1

Scheme 101

Pressing out taper roller bearing outer race

1. The outer race is pressed out together with the ring (item - 43 -, (Scheme 96) ), shim "S4" (item -42-, (Scheme 96) ) and the rubber washer for compensating length variations (item -44-, (Scheme 96) ).

Scheme 102

Scheme 103

Pressing off taper roller bearing inner race

1. Press off inner race with reverse gear sliding gear.

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 104

Pressing on taper roller bearing inner race

1. Install circlip before pressing on inner ring.

Scheme 105

Pressing off 5th gear and reverse gear synchro-hub

1. Remove circlip before pressing off.
2. Press off synchro-hub with 5th speed sliding gear.

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 106

Pressing off 4th gear wheel

1. Remove circlip before pressing off.

Scheme 107

Pressing off 3rd gear wheel

1. Remove circlip before pressing off.
2. Press 3rd gear wheel off with 2nd speed sliding gear.

A - Separating device 22-115 mm, e.g. Kukko 17/2

Scheme 108

Pressing off 1st and 2nd gear synchro-hub

1. Remove circlip before pressing off.
2. Press synchro-hub off with 1st speed sliding gear.

Scheme 109

Scheme 110

Scheme 111

1. The circlips for the synchro-hubs, needle bearings and individual gear wheels should be determined (Scheme 101) Circlip -1- secures the 1st and 2nd gear synchro-hub. (Scheme 111) Identification: color blue 1ST AND 2ND GEAR SYNCHRO-HUB CIRCLIP THICKNESS AVAILABILITY Circlip thickness (mm) 1.90 1.96 2.02 1.93 1.99 Circlip -2- secures the needle bearing/ 2nd speed sliding gear. (Scheme 111) Thickness: 2.00 mm. Identification: color blue Circlip -3- secures the 3rd gear wheel. NEEDLE BEARING/ 2ND SPEED SLIDING GEAR CIRCLIP THICKNESS AVAILABILITY Circlip thickness (mm) 1.90 1.98 2.06 1.94 2.02 Circlip -4- secures the 4th gear wheel. (Scheme 111) 4TH GEAR WHEEL CIRCLIP THICKNESS AVAILABILITY Circlip thickness (mm) 1.86 1.94 1.90 1.98 Circlip -5- secures the needle bearing/ 5th speed sliding gear. (Scheme 111) Thickness: 2.00 mm. Identification: color brown Circlip -6- secures the synchro-hub for 5th and reverse gear. (Scheme 111) Identification: color blue NEEDLE BEARING/ 5TH SPEED SLIDING GEAR CIRCLIP THICKNESS AVAILABILITY Circlip thickness (mm) 1.90 1.96 2.02 1.93 1.99 2.05 Circlip -7- secures needle bearing for reverse sliding gear. (Scheme 112) Thickness: 2.50 mm
2. Determine circlips according to table.

Inserting spring in sliding gear

The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.

Scheme 112

1. Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
2. Calculate average gap.

Scheme 113

The average gap must not be less than 0.5 mm.

Pressing on 1st and 2nd gear synchro-hub

Installation position: higher inner collar faces 2nd gear.

Scheme 114

Installation position of locking collar for 1st and 2nd gear

1. The chamfer (arrow -1-) faces 2nd gear.
2. The stepped side (arrow -2-) faces 1st gear.

Scheme 115

Pressing on 3rd gear wheel

Installation position: the groove on the gear wheel faces 4th gear.

Scheme 116

Pressing on 4th gear wheel

Installation position: higher inner collar faces 3rd gear.

Scheme 117

Pressing on 5th gear and reverse gear synchro-hub

Installation position: higher inner collar faces 5th gear

Scheme 118

Installation position of operating sleeve for 5th and reverse gear

1. Operating sleeves with chamfer -A- as well as operating sleeves with large offset -B- are installed.
2. Note allocation of operating sleeve to reverse idler gear. See «ALLOCATION OF OPERATING SLEEVE TO REVERSE IDLER GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__allocation-of-operating-sleeve-to-reverse) .
3. Installation position: Chamfer (arrow 1) faces reverse gear Small stepped side (arrow 2) faces 5th gear Large stepped side (arrow 3) faces reverse gear

Scheme 119

Allocation of operating sleeve to reverse idler gear

ALLOCATION OF OPERATING SLEEVE TO REVERSE IDLER GEAR

Reverse gear wheel, removing and installing

Note. The following list refers to items in (Scheme 122).

1. Circlip
2. Support plate
3. Reverse gear wheel Different versions, allocation, see «ALLOCATION OF OPERATING SLEEVE TO REVERSE IDLER GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__allocation-of-operating-sleeve-to-reverse)
4. Needle roller bearing
5. Thrust washer
6. Transmission cover With reverse gear shaft (arrow) To remove the reverse gear wheel it is not necessary to remove the reverse gear shaft The reverse gear shaft is not available as a replacement part
7. Torx bolt, 25 Nm Serves as an additional method of securing the reverse gear shaft

Scheme 120

Drive flange seal, replacing

1. Transmission installed

1. Observe general repair instructions. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .

1. Oil seal extractor lever VW 681
2. Drift VW 195
3. Drift VW 295
4. VAG1306 drip tray
5. T10037 puller

Note. The following procedure is for removal and installation of left seal. The same procedure is used for the left and right seals. A spacer ring is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm. See SETUP OF DRIVE FLANGE WITH POLYGON BEARING .

Scheme 121

1. Turn steering to left onto full lock stop.
2. Remove heat shields (arrows -1- and -2-) above right-hand drive axle.
3. If fitted, remove heat shield above left-hand drive axle.
4. Disconnect drive axle from flanged shaft.
5. Tie-up drive axle as high as possible. Do not damage paint on drive axle.
6. Place drip tray VAG1306 underneath transmission.

Note. To avoid damage to the needle bearings (polygon bearings) or differential during removal, the drive flange must be removed evenly, parallel and without one sided pressure

Removing left drive flange

1. Remove drive flange, to do so thread lower support of T10037 puller into housing (arrow).

Scheme 122

Remove right drive flange

1. Remove drive flange, to do so thread lower support of T10037 puller into housing (arrow).
2. Always replace drive flange circlip.
3. Clamp drive flange in vice, using soft jaws. Use new circlip -A- to press old circlip out of groove in drive flange.
4. Pull out drive flange oil seal with VW 681.

Scheme 123

Setup of drive flange with polygon bearing

Note. The following list refers to items in (Scheme 127).

1. Drive flange
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Retaining clip
5. Spacer ring - (is installed additionally if spline diameter is 30 mm)

Scheme 124

Note. Rough running of the polygon bearings with the drive flange removed is no sign for faulty bearings. An acoustic test can only be performed in installed condition. Watch for damage to the polygon bearings (for example, cracks in bearing outer ring). Polygon bearings can only be replaced together with drive flange. A spacer ring -5- is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm.

Scheme 125

1. Fill space between sealing and dust lips with multi-purpose grease.
2. Lightly oil outer circumference of seal.
3. Knock new right-hand drive flange oil seal in 5.5 mm below housing outer surface; do not cant seal when doing this.

Note. For repairs using old drive flange, oil seal must be pressed in to approx. 6.5 mm so that the new oil seal is not resting on the running surface of the old seal.

Scheme 126

1. Knock new left-hand drive flange oil seal in 6.5 mm below outer surface of cover using VW195; do not cant seal when doing this.

Note. For repairs using old drive flange, oil seal must be pressed in to approx. 6.5 mm so that the new oil seal is not resting on the running surface of the old seal.

1. Knock drive flange in with drift VW 295.
2. Bolt drive axle to drive flange.
3. Fit drive axle heat shields.
4. Check oil level in transmission. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level) .

Tightening torques

TORQUE SPECIFICATIONS: DRIVE AXLE

Oil seal for drive flange/driveshaft, replacing

1. Transmission installed

1. Observe general repair instructions. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .

1. Oil seal extractor lever VW 681
2. Mandrel 30-505
3. Installing tool 30-506 b
4. Ring spanner 7-piece set 3337
5. Drip tray VAG1306

Vehicles with 6-cylinder engine

Scheme 127

Scheme 128

Scheme 129

Scheme 130

1. Unscrew lambda probe on right exhaust pipe with special tool 3337 and move clear to the side.
2. Remove heat shields (arrows -1- and -2-) above right drive axle.
3. Unbolt front exhaust pipe with catalytic converter (right side) from exhaust manifold (3 nuts) -arrows
4. Remove heat shield for driveshaft from cover for Torsen differential -arrows-.
5. Unbolt driveshaft -1- from transmission and rest it on heat shield -2-. (Scheme 133)
6. Secure driveshaft to fuel pipe bracket -3- with wire -arrows-.
7. Place drip tray VAG1306 underneath and drain transmission fluid.
8. Place drip tray VAG1306 underneath plug.

Note. When plug -B- is removed, oil will run out. (Scheme 134)

Scheme 131

Scheme 132

1. Remove circlip -A-.
2. Screw an M8 bolt into thread of plug -B-.
3. Pull out plug -B- using bolt.
4. Open circlip and pull out drive flange.
5. Pull out drive flange oil seal with VW 681.

Scheme 133

Scheme 134

Scheme 135

1. Fill space between sealing lip and dust lip with a thin coat of G 052 128 A1 sealant.
2. Lightly oil outer circumference of seal.
3. Knock new drive flange oil seal in 2 mm below housing outer surface; do not cant seal when doing this.
4. Install drive flange.
5. When inserting drive flange, fit circlip at the same time. The circlip must be seated in the base of the groove.
6. Replace O-ring for plug.
7. Fit plug and secure in position.
8. Bolt on driveshaft. See «INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
9. Top up transmission oil in transmission and check oil level. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level) .
10. Adjust exhaust system free of tension. See appropriate Exhaust System article in ENGINES.

TORQUE SPECIFICATIONS

Speedometer sender and drive wheel, removing and installing

1. Transmission installed

1. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .

1. Pull connector off sender -A-.
2. Press retaining clip down, turn sender sideways and pull out upward.

Scheme 136

1. When installing replace seal -B-.
2. Insert sender and engage.
3. Handle sender carefully. If damaged it is possible that the speedometer will not indicate exactly.

Speedometer drive wheel, removing and installing

1. Drift VW 195
2. Drift VW 295
3. Extractor lever VW 681
4. Drip tray V.A.G 1306

1. Remove drive flange on left side. See «REMOVING LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-left-drive-flange) .
2. Remove speedometer sender. See «SPEEDOMETER SENDER AND DRIVE WHEEL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__speedometer-sender-and-drive-wheel-removing) .
3. Press retaining clips in direction of arrows with a screwdriver.
4. Remove drive wheel by levering out, alternating between sides.

Scheme 137

Installation is carried out in the reverse order, when doing this note the following

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.

Installation position

The drive peg of the drive wheel -A- faces to seal -B- and locates in the groove of the differential.

Scheme 138

The retaining clips (arrows) locate in the circumferential groove in differential.

1. Always replace seal -B- and circlip -C-. (Scheme 126)
2. Knock drive flange in with drift VW 295.
3. Top up oil in transmission and check oil level. See «SERVICE INTERVALS»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__service-intervals).

TORQUE SPECIFICATIONS: DRIVE AXLES

Differential, removing and installing

Special tools and equipment

1. VW771 slide hammer - complete set
2. Plug insert SW27 3257
3. Kukko 21/3 extractor

Note. Removal and installation is also possible with transmission installed. The differential can be installed and removed without removing shift mechanism, drive flange and drive pinion. Removal of the components mentioned above is necessary if the differential must be adjusted. Drive axles with polygon bearings are installed in all transmissions. Polygon bearings can only be replaced together with drive flange. Look for visible damage of polygon bearings. Rough running of the polygon bearings with the drive flange removed is no sign for faulty bearings. An acoustic test can only be performed in installed condition. A spacer ring is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm. (Scheme 146), Item -5-. Adjustments are required when replacing components marked with "1)". See ADJUSTMENT OVERVIEW.

Note. The following list refers to items in (Scheme 142).

1. Transmission housing
2. Oil seal Replace, see «REMOVING LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-left-drive-flange)
3. Circlip Replace Removing and installing, see «REMOVING AND INSTALLING CIRCLIP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-and-installing-circlip)
4. Spacer ring Is only fitted with drive axles that have a spline diameter of 30 mm Removing, see «REMOVING SPACER RING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-spacer-ring) Installing, see «INSTALLING SPACER RING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-spacer-ring)
5. Drive flange Removing and installing, see «REMOVING LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-left-drive-flange) Drive flange assembly, see «DRIVE FLANGE ASSEMBLY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__drive-flange-assembly)
6. Differential Can also be removed without removing transmission Disassembling and assembling, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-disassembling-and-assembling)
7. Cover Seal with AMV 188 000 02
8. Torx bolt,25 Nm
9. Speedometer drive wheel Removing and installing, see «SPEEDOMETER DRIVE WHEEL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__speedometer-drive-wheel-removing-and-installing) 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.

Scheme 139

Removing and installing circlip

1. Clamp drive flange in vice, using soft jaws. Use new circlip -A- to press old circlip out of groove in drive flange.

Scheme 140

Removing spacer ring

B - Internal puller 18.5-23.5 mm, e.g. Kukko 21/3

1. If the spacer ring is tight pull out using the multi-purpose tool VW 771.

Scheme 141

Installing spacer ring

1. Drive new spacer ring in onto stop, when doing this do not cant ring.

Scheme 142

Drive flange assembly

Note. The following list refers to items in (Scheme 146).

1. Drive flange
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Spacer ring - additionally fitted on shafts with 30 mm spline diameter
5. Circlip

Scheme 143

Note. The needle bearing (polygon bearing) does not turn easily when the drive axle is removed. This does not indicate that the bearing is faulty.

Differential, disassembling and assembling

Special tools and equipment

1. VW295 needle bearing drift
2. VW401 thrust plate
3. VW402 thrust plate
4. VW407 punch
5. VW408A punch
6. VW447H thrust pad
7. VW447I thrust pad
8. VW472/1 pressure piece
9. VW511 thrust pad
10. 30-11 thrust pad
11. 30-205 thrust pad
12. 40-21 sleeve
13. Thrust piece 40-105
14. Drift 3138
15. Press support 3144
16. Tube 3296
17. Sealant AMV 188 000 02
18. Kukko 20/10 two-arm puller or Kukko 44/2 puller
19. Kukko 204/2 two-arm puller

Note. Always replace both taper roller bearings together as a set. Adjustments are required when replacing components marked "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in (Scheme 147).

1. Transmission housing 1)
2. Shim "S2" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__adjustment-overview) .
3. Outer race for small taper roller bearing right 1) Driving out, see «KNOCKING RIGHT TAPER ROLLER BEARING OUTER RACE OUT OF TRANSMISSION HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__knocking-right-taper-roller-bearing-outer) Pressing in, see «PRESSING RIGHT TAPER ROLLER BEARING OUTER RACE INTO TRANSMISSION HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-right-taper-roller-bearing-outer)
4. Inner race for small taper roller bearing right 1) Pulling off, see «PULLING OFF RIGHT TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-off-right-taper-roller-bearing) Pressing on, see «PRESSING ON RIGHT TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-right-taper-roller-bearing)
5. Ring gear 1) Is mated to drive pinion (final drive set) Allocate according to transmission code using parts catalog. See «CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . Drive off housing with a drift. See «KNOCKING RING GEAR OFF HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . Fitting on differential housing, see «HEAT RING GEAR TO APPROX. 100° C WHEN INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__heat-ring-gear-to-approx-100deg)
6. Differential housing 1)
7. Bolt, 60 Nm + 1/4 turn (90°) further REPLACE bolt Lightly tighten bolts then tighten diagonally to correct torque
8. Inner race for large taper roller bearing left 1) Pulling off, see «PULLING OFF LARGE TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-off-large-taper-roller-bearing) Pressing on, see «PRESSING ON RIGHT TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-right-taper-roller-bearing)
9. Speedometer drive wheel Removing and installing, see «SPEEDOMETER DRIVE WHEEL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__speedometer-drive-wheel-removing-and-installing) 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.
10. Outer race for large taper roller bearing left 1) Knocking out, see «KNOCKING LEFT TAPER ROLLER BEARING OUTER RACE OUT OF COVER»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__knocking-left-taper-roller-bearing-outer) Pressing in, see «PRESSING LEFT TAPER ROLLER BEARING OUTER RACE INTO COVER»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-left-taper-roller-bearing-outer)
11. Shim "S1" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__adjustment-overview) .
12. Cover for differential 1) Seal with AMV 188 000 02
13. Sun wheel Installing, see «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-sun-wheels-and-planet-pinions)
14. Shaft for planet wheels Knock out with drift after removing spring pin
15. Spring pin For securing planet pinion axis shaft Version with annular groove: removing and installing, see «REMOVING AND INSTALLING SPRING PIN»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Version without annular groove: knock out with drift.
16. Planet pinion Installing, see «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-sun-wheels-and-planet-pinions)
17. One-piece thrust washer Coat with transmission oil when installing

Scheme 144

Knocking right taper roller bearing outer race out of transmission housing

1. Turn webs -A- and -B- out until they sit on the outer race within the recess in transmission.
2. After removing check shims for damage.

Scheme 145

Pressing right taper roller bearing outer race into transmission housing

1. Press piece VW 472/1 is fitted with the cone in the outer race.

Scheme 146

Pulling off right taper roller bearing inner race

A - Two-arm puller, e.g. Kukko 20/10

Scheme 147

Pressing on right taper roller bearing inner race

1. Heat inner race to approx. 100° C, place on and press in.

Scheme 148

Pulling off large taper roller bearing inner race

A - Two-arm puller, e.g. Kukko 204/2

Scheme 149

Pressing on left taper roller bearing inner race

1. Heat inner race to approx. 100°C, place on and press in.

Scheme 150

Knocking left taper roller bearing outer race out of cover

1. Turn webs -A- and -B- out until they sit on the outer race within the recess in transmission.
2. After removing check shims for damage.

Scheme 151

Pressing left taper roller bearing outer race into cover

1. Press piece 2050 is fitted with the cone in the outer race.

Scheme 152

Scheme 153

Heat ring gear to approx. 100° C when installing

1. When fitting ring gear, guide it with centralizing pins -A- (local manufacture).
2. Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to specified torque.

Scheme 154

Installing sun wheels and planet pinions

1. Lubricate one-piece thrust washer with transmission oil and install.
2. Insert sun wheels.
3. Insert planet pinions at 180° from their final position, and then rotate into place -arrow-.
4. Drive planet pinion axle into final position and secure.

Scheme 155

1. Spring pin with annular groove: pull out using side-cutting pliers.
2. Spring pin without annular groove: knock out from behind using a punch.

Scheme 156

1. Drive in spring pin as far as the stop.

Drive pinion and ring gear, adjusting

1. Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the final drive. For this reason, the drive pinion and ring gear are matched together during manufacture, and checked to ensure a good mesh pattern and quiet running in both directions of rotation. The position of quietest running is found by moving the drive pinion in an axial direction and at the same time lifting the ring gear out of the zero-play mesh position by the amount necessary to maintain the backlash within the specified tolerance.
2. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production.
3. The deviation, or tolerance "r", which is related to the master gauge "Ro", is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. The final drive set (drive pinion and ring gear) may only be replaced together as a matched pair.
4. Observe the general repair instructions for taper roller bearings and shims.
5. The friction torque measurement only serves to give a final check of the adjustment.

Final drive gear sets, adjusting and marking

1. Identification "0937" signifies an Oerlikon gear set with a ratio of 37:9
2. Pairing number (312) of final drive set
3. Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation "r" is always given in 1/100 mm. Example: "25" signifies r = 0.25 mm

Ro - Length of test machine master gauge used

Ro - For 170 mm dia. ring gear = 54.95 mm

R - Actual distance between ring gear axis and face of drive pinion in position of quietest running for this gear set

Vo -Hypoid offset

Scheme 157

Shims, position

Note. For adjustment overview when replacing individual components of transmission, see ADJUSTMENT OVERVIEW .

S1 - Shim for ring gear in cover for differential

S2 -Shim for ring gear in transmission housing

S3 -Shim for drive pinion in transmission housing

S4 -Shim for drive pinion in transmission cover

Scheme 158

Adjustment overview

Note. If repairs have been carried out to the transmission, it is only necessary to adjust the drive pinion, ring gear or final drive set if components have been replaced which have a direct effect on the adjustment of the final drive. Refer to the following table to avoid unnecessary adjustments

ADJUSTMENT OVERVIEW - FINAL DRIVE

Final drive set, sequence for readjusting

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

1. Determine total shim thickness "Stotal" for "S1" +"S2" (sets preload for taper roller bearings for differential). See «DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S1" + "S2"»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-total-shim-thickness-stotal-for) .
2. Determine total shim thickness "Stotal" for "S3" + "S4" (sets preload for taper roller bearings for drive pinion). See «DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S3" + "S4"»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-total-shim-thickness-stotal-for) .
3. Distribute total shim thickness "Stotal" for "S3" + "S4" so that the distance from center of ring gear to face of drive pinion is the same as distance "R" which was determined during production from «DETERMINING THICKNESS OF SHIM "S3"»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-thickness-of-shim-s3) .
4. Distribute total shim thickness "Stotal" for "S1" + "S2" so that the specified backlash between ring gear and drive pinion is maintained from «DETERMINING THICKNESS OF SHIM"S2"»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__determining-thickness-of-shims2) .

Note. For overview of components and shims, see SHIMS, POSITION .

Scheme 159

Drive pinion, adjusting

Adjusting drive pinion and hollow shaft.

For repairs after which the drive pinion must be adjusted, see ADJUSTMENT OVERVIEW .

1. Lever VW 296
2. Measuring bar VW 385/1
3. Centering disc VW 385/3
4. Measuring plunger VW 385/14
5. Measuring plate VW 385/17
6. Master gauge VW 385/30
7. End dimension plate VW 385/33
8. Universal dial gauge bracket VW 387
9. Thrust plate VW 401
10. Punch VW 407
11. Sleeve VW 519
12. Installation arbor VW 792
13. Thrust pad 3062
14. Insertion sleeve 3182
15. Torque gauge 0-600 Ncm
16. Dial gauge
17. Dial gauge extension 6.5 mm
18. Dial gauge extension 30 mm

Determining total shim thickness "Stotal" for shims "S3" + "S4"

Setting preload of taper roller bearing for drive pinion with hollow shaft.

1. Differential removed

1. Press double taper roller bearing inner race -1- onto drive pinion and secure in place. See «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
2. Fit needle bearing -2-.
3. Fit circlip -3- onto hollow shaft and press on taper roller bearing inner race -4-. See «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
4. Fit drive pinion in hollow shaft.

Note. The hollow shaft is shown in the illustration without gears. The adjustment of the drive pinion can be performed either with or without the gears fitted.

Scheme 160

Scheme 161

1. Fit double taper roller bearing outer race for drive pinion in transmission housing without shims. See «PRESSING IN DOUBLE TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-double-taper-roller-bearing) .
2. Fit taper roller bearing outer race for drive pinion in transmission cover with shim "S4*" (1.0 mm thick). See «PRESSING ON DOUBLE TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

Scheme 162

Note. A shim "S4" with a thickness of 1.0 mm is fitted for initial measurements. It is referred to below as "S4*." When measurement "e" has been determined, the correct shim "S4" with the final thickness will be installed in place of "S4*." When taking measurements, always fit the rubber washer together with the ring for the rubber washer. See HOLDS RUBBER WASHER .

Scheme 163

Scheme 164

1. Fit fully assembled drive pinion with hollow shaft into transmission housing.
2. Fit transmission cover and tighten bolts to 25 Nm.
3. Turn transmission so that the transmission cover is downward.
4. Press down on face of pinion with lever VW 296 until taper roller bearing outer race contacts transmission cover.
5. While still maintaining pressure, rotate the drive pinion 5 turns in each direction in relation to the hollow shaft to settle the double taper roller bearing.
6. Then rotate the drive pinion together with the hollow shaft 5 turns in each direction to settle the taper roller bearing.
7. Assemble measuring equipment, use a 30 mm dial gauge extension.
8. Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.

Note. The dial gauge extension must contact the machined surface on the face of the pinion.

1. Turn transmission 180° so that the transmission cover is upward.
2. Rotate drive pinion together with hollow shaft 5 turns in each direction to settle the taper roller bearing. The measurement will otherwise not be correct.
3. Read off and note the play indicated on the dial gauge. Measurement in example: 0.45 mm

Note. If the measurement has to be repeated, first rotate the drive pinion with hollow shaft again 5 turns in each direction to settle the taper roller bearing. Then set the dial gauge to "0" again with 1 mm preload.

Scheme 165

Formula

"Stotal" = "S4*" + measurement + bearing preload

Example

Inserted shim "S4*" 1.00 mm

+ Measurement (example) 0.45 mm

+ Bearing preload (constant) 0.15 mm

= Total shim thickness "Stotal" for "S3" + "S4" 1.60 mm

Determining thickness of shim "S3*"

Formula

"S3*" = "Stotal" - "S4*"

Example

Total shim thickness "Stotal" for "S3" + "S4" 1.60 mm

Inserted shim "S4*" 1.00 mm

= Thickness of shim "S3*" 0.60 mm

Scheme 166

1. Remove double taper roller bearing outer race, fit shim "S3*" in transmission housing and install outer race again. See «PRESSING IN DOUBLE TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-double-taper-roller-bearing) .
2. Insert fully assembled drive pinion into transmission housing again.
3. Fit transmission cover and tighten bolts to 22 Nm.
4. To settle the taper roller bearings: rotate both the drive pinion and the hollow shaft 5 turns in each direction.
5. Fit measuring tools and secure with bolt (arrow) to transmission housing.
6. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
7. Loosen transmission cover bolts and turn drive pinion several times.
8. If the correct shims have been selected the dial gauge will now indicate the following value: 0.05-0.15 mm
9. Tighten transmission cover bolts again to 22 Nm.
10. Remove measuring tools.
11. To settle the taper roller bearings: rotate both the drive pinion and the hollow shaft 5 turns in each direction.

Determining measurement "e"

Note. Measurement "e" is required to determine the final shim thickness of "S3" and "S4."

Scheme 167

Scheme 168

Scheme 169

1. Set adjustment rings of universal mandrel VW 385/1 to the following measurements: Distance -a- = 35 mm Distance -b- = 75 mm
2. Assemble universal mandrel VW 385/1 as illustrated in (Scheme 171). Dial gauge extension -A-, 6.5 mm long Master gauge VW 385/30
3. Set master gauge VW 385/30 to Ro = 54.95 mm (for 170 mm dia. ring gear) and fit on universal mandrel.
4. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
5. Place end measuring plate on face of pinion.

Note. Ensure plate contact surface fits exactly and is free of oil.

Scheme 170

1. Remove master gauge and insert measuring mandrel in the housing. (Scheme 173) Dial gauge extension -A- = 6.5 mm long must be fitted Dial gauge faces toward cover for final drive
2. Fit cover for final drive and tighten 4 bolts to 25 Nm.
3. Using the adjustable ring, pull 2nd centering disc VW 385/2 out as far as possible so that the mandrel can still just be turned by hand.
4. Turn mandrel until the dial gauge plunger tip touches the end measuring plate on drive pinion head, then measure maximum deflection (return point). Measurement in following example "e" = 0.26 mm (in red scale on dial)

Note. Then, (after removing universal mandrel) check again that the dial gauge, with master gauge VW 385/30 in place, indicates "0" with 2 mm preload, otherwise correct adjustments.

Determining thickness of shim "S3"

Formula

"S3" = "S3*" + "r" + "e"

("e" in black scale)

or

"S3" = "S3*" + "r" - "e"

("e" in red scale)

Note. The deviation "r" (tolerance) related to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and inscribed on outer circumference of ring gear. If measurements are obtained on red scale then subtract value "e." If measurements are obtained on black scale then add value "e."

Example

Shim "S3*" already fitted 0.60 mm

+ Deviation "r" 0.38 mm

1. Value measured for "e" (red scale) 0.26 mm = Thickness of shim "S3" 0.72 mm
2. Determine shim(s) from table.

The following shims are available for "S3"

S3 SHIM THICKNESS AVAILABILITY

Determining thickness of shim "S4"

Formula

"S4" = "Stotal" - "S3"

Example

Total shim thickness "Stotal" for "S3" + "S4" 1.60 mm

Thickness of shim "S3" 0.72 mm

= Thickness of shim "S4" 0.88 mm

1. Determine shim(s) as accurately as possible from «S4 SHIM THICKNESS AVAILABILITY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) table.

Available shims for "S4"

S4 SHIM THICKNESS AVAILABILITY

Performing check measurement

Checking dimension "r"

Scheme 171

1. Install drive pinion with determined shims "S3" and "S4."
2. Turn hollow shaft against drive shaft, 5 rotations in each direction to seat the tapered roller bearing.
3. Turn hollow shaft with drive shaft, 5 rotations in both direction to seat the tapered roller bearing.
4. Insert universal mandrel "determining measurement'e" and perform check measurement.
5. Read off dial gauge anti-clockwise (red scale). If the shims have been correctly selected, the deviation "r" (marked on outer circumference of ring gear) must be shown - within a tolerance of +/- 0.04 mm.

Note. Then, (after removing universal mandrel) check again that the dial gauge, with master gauge VW 385/30 in place, indicates "0" with 2 mm preload, otherwise correct adjustments.

Measuring frictional torque (check)

Note. Drive pinion/hollow shaft tapered roller bearings are low friction bearings. Therefore the frictional torque has only a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal." Do not additionally oil new tapered roller bearing to perform the frictional torque measurement. These bearings have already been treated with a special oil by the manufacturer.

1. Fit torque gauge 0-600 Ncm on drive pinion.
2. Read off frictional torque.

Frictional torque specification

FRICTIONAL TORQUE SPECIFICATIONS

Scheme 172

Thickness of shim "S4" when replacing transmission cover, redetermining

Special tools, testers and auxiliary items required

1. Depth gauge (accurate to at least 5/100 mm)
2. Fitting tool VW 792/1
3. Universal dial gauge bracket VW 387
4. 2 x centering disc VW 385/3
5. Measuring plate VW 385/17
6. Dial gauge
7. Dial gauge extension

1. Clean housing flange.
2. Measure difference in depth "a" on old and new transmission cover.

Example

Scheme 173

Depth "a" (old transmission cover) 257.40 mm

Depth "a" (new transmission cover) 257.55 mm

= Difference 0.15 mm

1. Install thicker shim "S4" if the new transmission cover is deeper.
2. Install thinner shim "S4" if the old transmission cover is deeper.

Example

Previous shim "S4" 0.95 mm

+ Difference 0.15 mm

= New shim "S4" 1.10 mm

See S4 SHIM THICKNESS AVAILABILITY .

Scheme 174

1. Fit taper roller bearing outer race with shim "S4" in transmission cover. See «PRESSING OUT TAPER ROLLER BEARING OUTER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-out-taper-roller-bearing-outer) .
2. Insert fully assembled drive pinion into transmission housing again.
3. Fit transmission cover and tighten bolts to 22 Nm.
4. To settle the taper roller bearings: rotate both the drive pinion and the hollow shaft 5 turns in each direction.
5. Fit measuring tools and secure with bolt (arrow) to transmission housing.
6. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
7. Loosen transmission cover bolts and turn drive pinion several times.
8. If the correct shims have been selected the dial gauge will now indicate the following value: 0.05-0.15 mm

If this reading is not obtained the adjustment must be corrected.

Ring gear, adjusting

Adjusting differential

ADJUSTMENT OVERVIEW lists the repairs after which the ring gear has to be adjusted.

1. VW382/10 extension pin
2. VW385/17 magnetic plate
3. VW386A clamping piece
4. VW387 dial gauge holder
5. VW388 measuring lever
6. VW402 thrust plate
7. VW408A punch
8. VW472/1 pressure piece
9. VW521 adjustment tool for ring gear
10. Torque gauge 0-600 Ncm
11. Dial gauge
12. Dial gauge extension

Determining total shim thickness "Stotal" for shims "S1" + "S2"

Setting preload of taper roller bearings for differential.

1. Drive pinion removed

Note. If only the taper roller bearings for the differential are being replaced, the ring gear can be removed from the differential housing so the drive pinion does not have to be removed.

1. Remove seal and outer races of both taper roller bearings for differential.
2. Remove shims. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__differential-disassembling-and-assembling) .
3. Knock taper roller bearing outer race (small) with shim "S2" into transmission housing ( «PRESSING RIGHT TAPER ROLLER BEARING OUTER RACE INTO TRANSMISSION HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-right-taper-roller-bearing-outer) ). A shim "S2*" with a thickness of 1.20 mm (two 0.60 mm shims) is used for the measurement.

Note. For measurement purposes a shim "S2" of 1.20 mm is initially inserted which is designated "S2*" in the following. After determining backlash, "S2*" will be replaced by the correct shim "S2."

Scheme 175

Scheme 176

1. Press taper roller bearing outer race into cover for differential without shim "S1". See «PRESSING LEFT TAPER ROLLER BEARING OUTER RACE INTO COVER»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-left-taper-roller-bearing-outer) .
2. Insert differential without drive wheel for speedometer sender -G22 into transmission housing. The ring gear is positioned on the left-hand side (in front of cover for differential).
3. Install cover for differential with 4 bolts (22 Nm).
4. Position transmission so that the cover for differential faces up.
5. Turn differential 5 turns in both directions so that the taper roller bearings settle.
6. Assemble measuring equipment, use a 30 mm dial gauge extension.
7. Set dial gauge (3 mm measuring range) -A- to "0" with 2 mm preload.

Note. The tip of the dial gauge must be positioned on the center of the differential.

1. Lift differential, without turning, and read off play on dial gauge.

1. Measurement in following example: 0.62 mm.

Note. To lift the differential, attach special tools VW 521/4 and VW 521/12 on the right of the differential (housing side). If the measurement has to be repeated, the drive pinion with hollow shaft must be turned 5 turns in each direction first to settle the taper roller bearing.

Formula

"Stotal" = "S2*" + measurement + bearing preload

Example

Inserted shim(s) "S2*" 1.20 mm

+ Measured value 0.62 mm

+ Bearing preload (constant value) 0.30 mm

= Total thickness "Stotal"

for "S1" + "S2" 2.12 mm

Determining thickness of shim "S1*"

Note. The preliminary adjustment shim "S1*" will be replaced with the final shim "S1" after determining the backlash. The total shim thickness "Stotal" remains unchanged.

Formula

"S1*" = "Stotal" - "S2*"

Example

Total thickness "Stotal" for "S1" + "S2" 2.12 mm

Inserted shim(s) "S2*" 1.20 mm

= Thickness of shim "S1*" 0.92 mm

Note. Differential tapered roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal." Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with a special oil by the manufacturer. Drive pinion removed

1. Fit torque gauge 0-600 Ncm -A- onto differential.
2. Read off frictional torque.

Scheme 177

Frictional torque specifications

DIFFERENTIAL FRICTIONAL TORQUE SPECIFICATIONS

Note. If the final drive set (drive pinion and ring gear) is being readjusted, the adjustment of the drive pinion should be performed now, and the adjustment checked. See DRIVE PINION, ADJUSTING .

Measuring backlash

Position of ring gear in transmission housing.

1. Drive pinion with shims "S3*" and "S4*" fitted

Scheme 178

1. Install differential.
2. Turn the differential 5 turns in each direction to settle the taper roller bearings.
3. Secure dial gauge retainer VW 387 onto housing.
4. Attach ring gear adjusting device VW 521/4 and VW 521/12.
5. Fit dial gauge with dial gauge extension VW 382/10 (6 mm flat).
6. Adjust measuring lever VW 388 to distance "a" = 67 mm (for 170 mm dia. ring gear).
7. Determine play between the teeth flanks as follows: Turn ring gear until it makes contact with a tooth flank (end of backlash travel). Set dial gauge to "0" with 2 mm preload. Turn ring gear back until lying against an opposite tooth flank (backlash). Read off backlash and note value. Turn ring gear through 90 and repeat measurements a further 3 times.

Note. If the drive pinion rotates when the differential is turned, fit clamp VW 386A so that the backlash can be measured exactly. Loosen the clamp in order to turn the ring gear when repeating the measurement.

Determining average backlash

1. Add the four measured values together and divide by four.

Example

Scheme 179

1st measurement 0.28 mm

+ 2nd measurement 0.30 mm

+ 3rd measurement 0.30 mm

+ 4th measurement 0.28 mm

= Sum of measured values 1.16 mm

1. Result: The average backlash is 1.16 / 4 = 0.29 mm

Note. If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check installation, replace final drive set if necessary.

Determining thickness of shim"S2"

Formula

"S2" = "S2*" - backlash + lift

Example

Inserted shim "S2*" 1.20 mm

1. Average backlash 0.29 mm + Lift (constant) 0.15 mm = Thickness of shim "S2" 1.06 mm
2. Determine shim(s) from table.

The following shims are available for "S2"

S2 SHIM THICKNESS AVAILABILITY

Determining thickness of shim "S1"

Formula

"S1" = "Stotal" - "S2"

Example

Total shim thickness "Stotal" for "S1" + "S2" 2.12 mm

1. Thickness of shim "S2" 1.06 mm = Thickness of shim "S1" 1.06 mm
2. Determine shim(s) from table.

The following shims are available for "S1"

S1 SHIM THICKNESS AVAILABILITY

1. After installing shims "S1" and "S2", turn differential 5 turns in both directions so that the taper roller bearings settle.
2. Measure backlash four times on circumference. Specifications: 0.12-0.22 mm

Scheme 180

Note. If the backlash lies outside the tolerances, the adjustments must be repeated. But the total shim thickness "Stotal" must remain the same. The individual measurements must not differ by more than 0.06 mm from each other.

Driveshaft, servicing

1. Do not bend the driveshaft more than 25° at the central joint, otherwise the universal joint will be damaged.
2. Only store and transport driveshaft extended.
3. Observe general repair instructions. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .
4. No repair work can be carried out on the driveshaft with the exception of removing, installing and adjusting.
5. If the driveshaft is only detached at the transmission or from the rear final drive, it must be tied-up or supported at the constant velocity joints.
6. Work on the driveshaft should be carried out on a vehicle hoist.
7. Before removing, mark the positions of all parts in relation to each other. Reinstall in the same position otherwise imbalance will be excessive, the mountings could be damaged causing rumbling noises.
8. If a problem exists (noise or vibrations), first check whether correct adjustment of the driveshaft rectifies the fault before replacing the driveshaft.
9. 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.

Note. The following list refers to items in (Scheme 187).

1. Rear final drive
2. Driveshaft
3. Gasket Replace Pull off backing foil, and stick self-adhesive side of gasket to drive flange
4. Lock plate
5. Hexagon socket head bolt, 55 Nm Self-locking Replace The bolt threads in the drive flanges must always be cleaned (e.g. with a thread tap)
6. Shim Determining thickness, see «DRIVESHAFT, ADJUSTING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
7. Nut, 25 Nm
8. Stud, 10 Nm Do not remove
9. Transmission

Scheme 181

Scheme 182

Scheme 183

1. Assembly stand 3213
2. Spacers 3139/3

Scheme 184

Scheme 185

Scheme 186

1. Observe notes under «DRIVESHAFT, SERVICING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driveshaft-servicing) .
2. If fitted, remove cross-piece below exhaust system.
3. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s))
4. Remove driveshaft heat shields from body -arrows-.
5. Remove heat shield for driveshaft from cover for Torse differential -arrows-.
6. Check whether there is a factory marking (paint) on the driveshaft and driveshaft/rear final drive flange. If not, mark position of driveshaft flange -arrow A- in relation to rear final drive -arrow B- with paint.
7. Unscrew the three upper securing bolts on each driveshaft constant velocity joint.
8. Attach assembly appliance 3213 with spacers 3139/3, and tighten the plastic nuts. NOTE: Never fit assembly appliance onto balance plates.
9. Remove the three remaining bolts from the front and rear constant velocity joints.
10. Unscrew securing nuts (arrows) for center bearing and take off driveshaft together with assembly appliance. NOTE: Driveshaft must always be kept in extended position for transportation and storage.

Scheme 187

Installation is carried out in the reverse order, when doing this note the following

Scheme 188

1. To prevent imbalance, the flanges on the driveshaft -arrow A- and on the rear final drive -arrow B- must be installed so that the factory markings (or the markings made on removal) are in alignment.
2. If a new driveshaft is being installed and the factory marking on the rear final drive flange is no longer visible, the radial run-out at the flange for the driveshaft must be measured. See «MEASURING RADIAL PLAY AT FLANGE/DRIVE SHAFT AND MARK»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . The colored marking on the driveshaft must be aligned with the marking on the flange.
3. Replace gaskets on drive flanges (pull off backing foil and stick gasket onto flange).
4. After removing the driveshaft from the rear final drive, the additional balance disc (thick washer) that may be located between the base plate and the bolt head must not be reinstalled.
5. After removing the driveshaft, it is important to clean any remaining locking compound out of the threads in the drive flanges on the transmission and rear final drive. If this is neglected, the new bolts can seize when they are screwed in and shear off later if they have to be removed.
6. The threads can be cleaned with a thread tap.
7. REPLACE DRIVESHAFT BOLTS (self-locking).

1. Align exhaust system so it is free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: DRIVESHAFT

1. VW387 dial gauge holder
2. Dial gauge
3. Bolt M10 x 85

Scheme 189

Note. 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. See INSTALLING . Radial run-out can also be measured with the rear final drive installed, however the drive shaft must be disconnected from the rear final drive. See notes under DRIVESHAFT, SERVICING .

Scheme 190

1. Attach VW387 dial gauge holder with dial indicator to connection between crossmember and final drive.
2. Set dial indicator onto ground diameter -arrow- in drive shaft flange and set to "0" with 1 mm preload.
3. Turn differential via both rear wheels (right and left drive flanges) in one direction until the drive shaft flange has made one complete revolution.
4. Mark largest radial run-out on outer edge of flange with colored marking (equivalent to largest distance from turning axis).
5. Remove old marking on drive shaft flange.
6. Install drive shaft. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

Scheme 191

1. Assembly stand 3213
2. Spacers 3139/3

Scheme 192

Adjusting

Adjustments should be carried out with care, because a badly adjusted driveshaft is often the cause of vibration and droning.

Scheme 193

Scheme 194

Scheme 195

Scheme 196

1. Observe notes under «DRIVESHAFT, SERVICING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driveshaft-servicing) .
2. If fitted, remove cross-piece below exhaust system.
3. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s)): See appropriate Exhaust System article in ENGINES.
4. Remove driveshaft heat shields from body -arrows-.
5. Attach assembly appliance 3213 with spacers 3139/3, and tighten the plastic nuts. NOTE: Never fit assembly appliance onto balance plates.
6. Unscrew securing nuts -arrows- for center bearing. NOTE: Do NOT remove stud.
7. Align center driveshaft bearing so that distance -a- is the same on both sides.
8. Measure distance -a-.
9. Select shims from table.

The following shims are available

DRIVE SHAFT ADJUSTMENT SHIM THICKNESS AVAILABILITY

1. Install the correct shims on both sides.

Scheme 197

Scheme 198

1. Loosen plastic nuts of installation device -arrows A- far enough so that the bracket for intermediate bearing -1- has some clearance -a- to stud -2-.
2. Insert determined adjustment shim -1- and swing bracket for intermediate bearing -2- to other side.
3. Place second adjustment shim -4- onto stud -3-.
4. Now tighten both plastic nuts of installation device -arrow A- again.

Scheme 199

1. Using assembly appliance, push driveshaft toward the rear as far as it will go.
2. Mark position of center bearing in relation to body (arrow -A-).
3. Using assembly appliance, push driveshaft toward the front as far as it will go.
4. Mark position of center bearing in relation to body (arrow -B-).
5. Align driveshaft -arrow C-. The center bearing must be aligned centrally between markings -A- and -B-.
6. Bolt on center bearing in center position (arrow -C-), tighten to 25 Nm.
7. Take off assembly appliance.

The remaining installation steps are carried out in the reverse sequence - note the following points

1. Align exhaust system so it is free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: FRONT CROSS-PIECE

Oil level in rear final drive, checking

Special tools and equipment

1. Drip tray V.A.G 1306

Scheme 200

Scheme 201

1. Remove plug (arrow) to check oil. Specification: oil level up to lower edge of filler hole
2. Top-up gear oil if necessary. For specification, see «CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
3. Fit oil filler plug.

Tightening torque

Oil filler plug: 35 Nm

1. Drift 2062

Scheme 202

1. Observe general repair instructions. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .

Note. All the illustrations show the left side of the final drive. Removal and installation is the same for the drive flange and seal on the right-hand side.

1. Rear final drive installed

Scheme 203

1. Remove heat shields from final drive (arrows).
2. Place drip tray underneath.
3. Unbolt drive shaft.
4. To loosen the securing bolt, screw two bolts into the drive flange and counter-hold with a lever.
5. Lever seal out with a lever.

Installation is carried out in the reverse order, when doing this note the following

Scheme 204

1. Lightly oil outer circumference of seal.
2. Drive new seal in onto stop, when doing this do not cant seal.
3. Fill space between seal and dust lip with a thin layer of G 052 128 A1 sealant.
4. Top-up gear oil in rear final drive and check oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .

TIGHTENING TORQUES: DRIVE FLANGE, REAR FINAL DRIVE

Scheme 205

1. Engine/transmission lift VAG 1383A with universal mount VAG1359/2
2. Retainer 3028
3. Puller VW 391
4. Multi-purpose tool VW 771
5. VW 771/37
6. Drift 3026
7. Seal driver 3143

Scheme 206

Requirements

1. Rear final drive installed

1. Observe general repair instructions. See «REPAIR INSTRUCTIONS, GENERAL»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__repair-instructions-general) .

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

1. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s)): See appropriate Exhaust System article in ENGINES.
2. Check whether there is a factory marking (paint) on the driveshaft. If not, mark position of driveshaft flange -arrow A- in relation to rear final drive -arrow B- with paint.
3. Unbolt driveshaft from rear final drive and tie up driveshaft to exhaust mounting brackets.
4. Position transmission jack V.A.G 1383 A with universal transmission attachment 1359/2 under final drive and take up weight of final drive.
5. Remove securing bolts -arrows- of left final drive support.
6. Carefully lower final drive until the flange is accessible.
7. Mark position of drive pinion retaining nut with paint.
8. In order to check the installation when reassembling, measure and note the following dimensions with depth gauge: Dimension a = distance flange/drive pinion. (Scheme 216) Dimension b = distance flange/drive pinion nut NOTE: Illustrations show the final drive removed for the following work sequence.
9. Fit counter-hold tool 3028 and remove drive pinion nut.
10. Place drip tray underneath.
11. Pull off flange with special tool VW 391.
12. Screw two M8 x 30 hexagon bolts -A- into flange.
13. Pull out seal.

Installation is carried out in the reverse order, when doing this note the following

Scheme 213

Scheme 214

Scheme 215

Scheme 216

1. Replace O-ring between drive pinion bearing and flange.
2. Lightly oil O-ring before installing.
3. Lightly oil outer circumference of seal.
4. Drive in seal for driveshaft flange onto stop with drift 3026.
5. Fill space between sealing and dust lips with a thin layer of G 052 128 A1 sealant.
6. Drive driveshaft flange onto drive pinion until retaining nut can be fitted.
7. Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with locking fluid D 000 600. NOTE: Use the originally fitted hexagon nut to secure the flange on the drive pinion, otherwise it will not be possible to reproduce the original installation position.
8. Tighten drive pinion nut exactly onto previously marked position.
9. To ensure that the assembly is correct, perform check measurement of dimensions -a- and -b-. Maximum permissible deviation from original measurements: + 0.5 mm
10. Secure hexagon nut in position.
11. Top-up gear oil in rear final drive and check oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .
12. If there was no factory marking on the driveshaft (paint) and the position of the driveshaft in relation to the driveshaft flange was therefore marked on removal, reinstall the driveshaft in the same position. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
13. If there is a factory marking on the driveshaft, measure the radial run-out at the driveshaft flange on the final drive. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . Align the paint marking on the driveshaft with the new marking on the flange.

Note. After removing the driveshaft from the rear final drive, the additional balance disc (thick washer) that may be located between the base plate and the bolt head must not be reinstalled. After removing the driveshaft, it is important to clean any remaining locking compound out of the threads in the drive flanges on the transmission and rear final drive. If this is neglected, the new bolts can seize when they are screwed in and shear off later if they have to be removed. The threads can be cleaned with a thread tap. REPLACE driveshaft bolts (self-locking).

1. Replace seal at flange/driveshaft and tighten prop shaft. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
2. Aligning exhaust system free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: DRIVE SHAFT FLANGE

1. Transmission jack V.A.G 1383 A with universal transmission attachment V.A.G 1359/2

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

1. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s)): See appropriate Exhaust System article in ENGINES.
2. Check whether there is a factory marking (paint) on the driveshaft. If not, mark position of driveshaft flange -arrow A- in relation to rear final drive -arrow B- with paint.
3. Unbolt driveshaft from rear final drive and tie up driveshaft to exhaust mounting brackets.
4. Remove heat shields from rear final drive -arrows-.
5. Unbolt left and right drive axles and rest them on the suspension links.
6. Place transmission jack V.A.G 1383 A with universal transmission attachment 1359/2 under final drive and take up weight of final drive.
7. Remove securing bolts -arrows- of left final drive support.
8. Unscrew socket head bolts (arrows) at rear crossmember.
9. Lower rear final drive.

Scheme 222

Installation is carried out in the reverse order, when doing this note the following

1. ALWAYS REPLACE self-locking nuts.
2. It is essential that the residues of locking fluid are cleaned out from the threads in drive flange on the rear final drive after removing the driveshaft. Otherwise there is a danger that new bolts will seize and then shear off when removing them again.
3. The threads can be cleaned with a thread tap.
4. REPLACE DRIVESHAFT BOLTS (self-locking).
5. After removing the driveshaft from the rear final drive, the additional balance disc (thick washer) that may be located between the base plate and the bolt head must not be reinstalled.
6. Replace gaskets on drive flange (pull off backing foil and stick gasket to drive flange).
7. To prevent imbalance, the flanges must be installed so that the paint markings arrows -A- and -B- are in alignment. See «INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

Scheme 223

1. Top up gear oil in rear final drive and check oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .
2. Align exhaust system so it is free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: REAR FINAL DRIVE

Scheme 224

TIGHTENING TORQUES: Drive Shaft

1. Engine and transmission lift VW 540

Scheme 225

Securing rear final drive

1. Secure complete rear final drive on a repair stand with bracket VW 540.

Scheme 226

Assembly overview

Note. The following list refers to items in (Scheme 235).

1. Final drive housing
2. Spacer sleeve Replace
3. Flange for driveshaft Removing and installing, see «DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
4. Drive pinion Is mated with ring gear, always replace together as a set Removing and installing, see «DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
5. Cover for final drive
6. Differential Removing and installing, see «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Disassembling and assembling, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
7. Ring gear Is mated to drive pinion (final drive set) Removing and installing, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)

Scheme 227

Note. General repair instructions, see REPAIR INSTRUCTIONS, GENERAL . Adjustments are required when replacing components marked "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in (Scheme 236).

1. Breather sleeve With rubber valve Installation position, see «POSITION OF BREATHER SLEEVE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__position-of-breather-sleeve)
2. Final drive housing 1) Removing and installing drive pinion, see «DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
3. Outer race for large taper roller bearing 1) Removing and installing, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
4. Shim "S1" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
5. Cover for final drive 1) With O-ring Replace O-ring Lubricate O-ring with oil when installing
6. Torx bolt, 25 Nm
7. Seal, right See «DRIVE FLANGE OIL SEALS, REPLACING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
8. Hexagon socket head bolt, 25 Nm
9. Drive flange, right Removing and installing, see «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
10. Oil filler plug, 35 Nm Checking rear final drive oil level, see «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive)
11. Differential with ring gear 1) Disassembling and assembling, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
12. Oil drain plug, 35 Nm
13. Bush Holds magnet in position Knock-in onto stop
14. Magnet
15. Outer race for small taper roller bearing 1) Removing and installing, see «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
16. Shim "S2" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
17. Seal, left See «DRIVE FLANGE OIL SEALS, REPLACING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
18. Drive flange, left Removing and installing, see «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
19. Hexagon socket head bolt, 25 Nm
20. Cover Installing, see «PRESS COVER ONTO STOP»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)

Scheme 228

1. To remove mounting bolt, insert 2 bolts in the drive flange and counterhold using mounting lever.
2. Mark drive flange (left and right) and remove.

Scheme 229

Scheme 230

Position of breather sleeve

The breather sleeve should project 13 mm (distance "a") out of the housing after pressing in.

The slot in the rubber valve should be in line with the direction of travel.

Scheme 231

1. Collecting pan VAG 1306

Scheme 232

1. Rear final drive removed

Scheme 233

1. Secure complete rear final drive on a repair stand with bracket VW 540. See «REAR FINAL DRIVE, SECURING TO REPAIR STAND»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
2. Place drip tray underneath to collect oil.
3. Drain gear oil.
4. Remove left and right-hand drive flanges.
5. To loosen the securing bolt, screw two bolts into the drive flange and counter-hold with a lever.
6. Mark drive flanges (left and right) and pull out.
7. Unscrew securing bolts from cover for final drive.
8. Take cover for final drive off axle housing and remove differential.

Install in reverse order.

1. Insert differential.
2. Replace O-ring for cover for final drive and oil when installing.
3. Fit cover for final drive on final drive housing and tighten in diagonal sequence to 25 Nm.
4. Fill space between sealing and dust lips with a thin layer of G 052 128 A1 sealant.
5. Install drive flanges and tighten to 25 Nm.
6. Top-up gear oil in rear final drive and check oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__oil-level-in-rear-final-drive) .

Prepare the following special tools and test equipment

Scheme 234

Scheme 235

Scheme 236

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. Sleeve 40-21
9. Thrust piece 40-105
10. Thrust plate 2050
11. Drift 3138
12. Kukko 44/2 two-arm puller
13. VAG1582 taper roller bearing puller
14. VAG1582/6 attachment to VAG1582

Scheme 237

Note. See REPAIR INSTRUCTIONS, GENERAL . Secure final drive on a repair stand. See REAR FINAL DRIVE, SECURING TO REPAIR STAND . Always replace both taper roller bearings together as a set. Adjustments are required when replacing components marked "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in (Scheme 246).

1. Cover for final drive 1)
2. O-ring Replace Lubricate with oil when installing
3. Final drive housing 1)
4. Shim "S1" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
5. Outer race for small taper roller bearing 1) Knocking out, see «KNOCKING OUTER RACE OF SMALL TAPER ROLLER BEARING OUT OF HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__knocking-outer-race-of-small-taper) Pressing in, see «PRESSING OUTER RACE OF SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING (PRESS TO STOP)»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
6. Inner race for small taper roller bearing 1) Pulling out, see «PRESSING DRIVE PINION OUT OF INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Pressing in, see «PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-inner-race-for-small)
7. Bolt, 60 Nm + turn 45° further REPLACE bolt Allocation, see parts catalog Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential housing 1)
9. Ring gear 1) Paired with drive pinion (final drive set) Select correct version according to code letters. Drive off housing with a punch, see «DRIVING RING GEAR OFF HOUSING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Installing on differential housing, see «INSTALLING RING GEAR»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-ring-gear)
10. Spring pin For securing planet pinion axis shaft Drive in flush
11. Inner race for large taper roller bearing 1) Pulling off, see «PULLING OFF INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-off-inner-race-for-large) Pressing on, see «PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-inner-race-for-large)
12. Outer race for large taper roller bearing 1) Driving out, see «DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driving-outer-race-for-large-taper) Pressing in, see «PRESSING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
13. Shim "S2" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
14. Threaded piece
15. Sun wheel Installing, see «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Adjusting, see «ADJUSTING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
16. Planet pinion Installing, see «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
17. Planet pinion axis shaft Knock out with drift
18. Shim Re-determining thickness, see «ADJUSTING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a)
19. Thrust washer Check for cracks

Scheme 238

Knocking outer race of small taper roller bearing out of housing

1. After removing check shims for damage.

Scheme 239

Scheme 240

Pulling off inner race for small taper roller bearing

1. Two arm puller, e.g. Kukko 44/2

Scheme 241

Pressing on inner race for small taper roller bearing

1. Heat bearing to approx. 100° C, fit in position and press home.

Scheme 242

Pulling off inner race for large taper roller bearing

1. Before fitting the extractor position press piece 40-105 on differential housing.

Scheme 243

Pressing on inner race for large taper roller bearing

1. Heat bearing to approx. 100° C, fit in position and press home.

Scheme 244

Driving outer race for large taper roller bearing out of cover

1. After removing check shims for damage.

Scheme 245

Scheme 246

Scheme 247

Installing ring gear

1. Use centering pins -A- (local manufacture) as a guide.
2. Heat ring gear to approx. 100°C and install.

Scheme 248

Scheme 249

1. If the sun wheels have been replaced, measure and select new shims. See «ADJUSTING SUN WHEELS AND PLANET PINIONS»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
2. Insert sun wheels with the measured shims.
3. Install planet pinions at 180° from their final position, and rotate into place -arrow-.
4. Fit and align thrust washers.
5. Insert threaded pieces.
6. Drive planet pinion axis shaft into final position and secure.

Scheme 250

1. Insert sun wheels with thinnest shims (0.5 mm).
2. Insert planet pinions with thrust washers at 180° from their final position. NOTE: Do not now interchange planet pinions and thrust washers.
3. Drive in planet pinion axis shaft.
4. Press planet pinions outward.
5. Press sun wheels in direction indicated (arrows), and check the amount of play.
6. Determine the thickest shims for the sun wheels (on each side) which can still just be inserted.
7. Select shims of equal thickness.
8. Identify shims according to the table.

The following shims are available

SUN WHEEL AND PLANET PINION SHIM THICKNESS AVAILABILITY

Note. The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the sun wheels and planet pinions -arrow-.

Scheme 251

1. VAG1383A engine/transmission hoist
2. VAG1359/2 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. VW 771 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 separating tool
23. Kukko 21/7 extractor
24. Kukko 22/2 support
25. Torque gauge 0-600 Ncm
26. 36 mm long socket

Note. Secure final drive on a repair stand. See REAR FINAL DRIVE, SECURING TO REPAIR STAND . Always replace both taper roller bearings together as a set. Adjustments are required when replacing components marked "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in (Scheme 260).

1. Nut Removing, see «REMOVING NUT FOR DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-nut-for-drive-pinion) Installing, see «TIGHTENING NUT FOR DRIVE PINION AND MEASURING FRICTION TORQUE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__tightening-nut-for-drive-pinion-and) Measuring friction torque, see «MEASURING FRICTION TORQUE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__measuring-friction-torque) Securing, see «SECURING DRIVE PINION NUT»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__securing-drive-pinion-nut)
2. Flange for driveshaft Removing, see «PULLING FLANGE FOR DRIVESHAFT OFF DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-flange-for-driveshaft-off-drive) Installing, see «INSTALLING FLANGE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-flange)
3. Oil seal Removing, see «PULLING FLANGE FOR DRIVESHAFT OFF DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-flange-for-driveshaft-off-drive) Driving in, see «DRIVING IN SEAL FOR FLANGE FOR DRIVESHAFT»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driving-in-seal-for-flange-for)
4. O-ring Replace Lubricate with transmission oil when installing. See «INSTALLING O-RING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__installing-o-ring) .
5. Inner race for small taper roller bearing 1) Pressing out drive pinion, see «PRESSING DRIVE PINION OUT OF INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Installing, see «PRESSING ON SMALL TAPER ROLLER BEARING INNER RACE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-on-small-taper-roller-bearing)
6. Outer race for small taper roller bearing 1) Pulling out, see «PULLING OUT OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-out-outer-race-for-small) Pressing in, see «PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-in-outer-race-for-small)
7. Spacer sleeve 1) Replace
8. Final drive housing 1)
9. Shim "S3" Note thickness See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
10. Outer race for large taper roller bearing 1) Driving out, see «DRIVING OUT OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__driving-out-outer-race-for-large) Pulling in, see «PULLING IN OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pulling-in-outer-race-for-large)
11. Inner race for large taper roller bearing 1) Pulling off, see «PRESSING INNER RACE FOR LARGE TAPER ROLLER BEARING OFF DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) Pressing on, see «PRESSING INNER RACE FOR LARGE TAPER ROLLER BEARING ONTO DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__pressing-inner-race-for-large-taper)
12. Drive pinion 1) Is mated with ring gear, always replace together as a set

Scheme 252

Removing nut for drive pinion

1. Screw in two M8 x 30 hexagon bolts -A-. B - Socket attachment (long) 36 mm A/F
2. The final drive must be supported when loosening the nut (e.g. using universal transmission attachment V.A.G 1359/2 in combination with transmission jack V.A.G 1383 A).

Scheme 253

Pulling flange for driveshaft off drive pinion

1. Screw two M8 x 30 hexagon bolts -A- into the flange.

Scheme 254

Scheme 255

Scheme 256

Pulling out outer race for small taper roller bearing

A - Counter support e.g. Kukko 22/2

B - Internal puller 46-58 mm, e.g. Kukko 21/7

Scheme 257

Driving out outer race for large taper roller bearing

1. After removing check shims for damage.

Scheme 258

Scheme 259

A - Separating device 22-115 mm, e.g. Kukko 17/2

Pressing inner race for large taper roller bearing onto drive pinion

1. Heat bearing to approx. 100°C, fit in position and press home.

Scheme 260

Pulling in outer race for large taper roller bearing

1. First insert predetermined shim "S3" for drive pinion. See «ADJUSTMENT OVERVIEW»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . NOTE: The marking "Oben" on thrust piece 3253/4 goes toward the nut of the puller.

Scheme 261

Pressing in outer race for small taper roller bearing

1. Lubricate outer race with oil and fit using punch VW 408A and thrust plate 30-205.

Scheme 262

Pressing on small taper roller bearing inner race

1. Insert drive pinion with new spacer sleeve.
2. Heat inner race for small taper roller bearing to approx. 100 ° C and fit onto drive pinion.
3. Press up drive pinion and insert bearing with thrust plate 40-21 onto stop.

Scheme 263

Installing O-ring

1. Lubricate O-ring with transmission oil and install.

Scheme 264

Driving in seal for flange for driveshaft

1. Lightly oil outer circumference of seal.
2. Fill space between sealing and dust lips with a thin layer of G 052 128 A
3. Drive in seal onto stop with drift 3026.

Scheme 265

Installing flange

1. Knock flange for driveshaft onto drive pinion until the nut can be fitted.

Scheme 266

Tightening nut for drive pinion and measuring friction torque

1. Screw in two M8 x 30 hexagon bolts -A-. B - Socket attachment (long) 36 mm A/F
2. The final drive must be supported when loosening the nut (e.g. using universal transmission attachment V.A.G 1359/2 in combination with transmission jack V.A.G 1383 A).

Scheme 267

Note. Increase tightening torque slowly and check friction torque at regular intervals, if the specified friction torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.

Measuring friction torque

With torque gauge, 0-600 Ncm, commercially available

B - Socket attachment, 36 mm A/F

Note. Use adapter 3/4 to 1/2 if necessary.

Scheme 268

1. The following friction torques should be set

FRICTION TORQUE SPECIFICATIONS: REAR FINAL DRIVE

Securing drive pinion nut

1. After securing the nut, measure radial run-out at flange for driveshaft. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

Scheme 269

1. Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the final drive. For this reason, the drive pinion and ring gear are matched together during manufacture, and checked to ensure a good mesh pattern and quiet running in both directions of rotation. The position of quietest running is found by moving the drive pinion in an axial direction and at the same time lifting the ring gear out of the zero-play mesh position by the amount necessary to maintain the backlash within the specified tolerance.
2. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production.
3. The deviation, or tolerance "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. The final drive set (drive pinion and ring gear) may only be replaced together as a matched pair.
4. Observe the general repair instructions for taper roller bearings and shims.
5. Maximum care and cleanliness are essential for achieving good results when performing repairs and taking measurements.

Gear sets, adjusting and marking

Note. The following list refers to items in (Scheme 278).

1. Identification "0937" signifies an Oerlikon gear set with a ratio of 37:9
2. Gear set pairing number (312
3. Deviation (tolerance) "r" is based on the test machine master gauge used in the production. The deviation "r" is always given in 1/100 mm. Example: "25" signifies r = 0.25 mm Ro - Length of master gauge used for test machine "Ro" Ro - Ring gear = 57.50 mm R - Actual dimension between center axis of ring gear and face of pinion at point with quietest running for this gear set. R = Ro + r Vo - Hypoid offset

Scheme 270

Readjusting final drive set, recommended sequence

The following work sequence is recommended to save time when the drive pinion and ring gear have to be adjusted

1. Determine total shim thickness "Stotal" for "S1" + "S2" for the specified preload for taper roller bearings for differential.
2. Determine total shim thickness "S3" to reproduce the installation position for the drive pinion determined on the test machine in production.
3. Distribute total shim thickness "Stotal" for "S1" + "S2" so that the specified backlash exists between ring gear and drive pinion.

Note. For an overview of components and shims, see SHIMS, POSITION .

Note. If repairs have been carried out on the final drive it is only necessary to adjust the drive pinion or final drive set if components have been replaced which have a direct effect on the adjustment of the final drive. Refer to the following table to avoid unnecessary adjustments

ADJUSTMENT OVERVIEW - REAR FINAL DRIVE

Note. For an adjustment overview when replacing individual components of final drive, see ADJUSTMENT OVERVIEW .

S1 - Adjustment shim for ring gear in cover for final drive

S2 - Adjustment shim for ring gear in final drive housing

S3 - Adjustment shim for drive pinion in final drive housing

Scheme 271

1. Engine/transmission lift VAG 1383A
2. Universal mount VAG 1359/2
3. Universal mandrel VW 385/1
4. centering disc VW 385/2
5. centering disc VW 385/3
6. Measuring plunger VW 385/14
7. Dial gauge extension VW 385/15
8. Master gauge VW 385/30
9. End dimension plate VW 385/33
10. Thrust plate VW 401
11. Thrust plate VW 402
12. Punch VW 408A
13. Support channels VW 457
14. Holding fixture VW 540
15. Thrust pad 30-205
16. Seal installer 2003/3
17. Thrust pad 3005
18. Retainer 3028
19. Thrust pad 3062
20. Wheel bearing assembly set 3253 with 3253/3 and 3253/4
21. Dial gauge

Note. Adjust ring gear (determine total shim thickness "Stotal" for shims "S1" + "S2" using RING GEAR, ADJUSTING ) before adjusting drive pinion. The drive pinion only has to be readjusted if the final drive set (ring gear and drive pinion), the taper roller bearings for the drive pinion or the final drive housing are replaced. See ADJUSTMENT OVERVIEW . Do not oil new tapered roller bearings for the friction torque measurement. The bearings were already treated with a special oil at the factory.

Determine thickness of shim "S3"

Setting preload of taper roller bearing for drive pinion.

Scheme 272

Scheme 273

1. Mount final drive on repair stand. See «REAR FINAL DRIVE, SECURING TO REPAIR STAND»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
2. Pull outer race of large taper roller bearing into housing (without shim). NOTE: The marking "Oben" on thrust piece 3253/4 faces the nut of the puller.
3. Pull outer race for small taper roller bearing into housing.
4. Lubricate outer race with oil and fit using drift VW 408A and thrust plate 30-205.
5. Insert drive pinion without spacer sleeve.
6. Heat inner race for taper roller bearing to approx. 100°C and fit onto drive pinion.

Scheme 274

Note. Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with a special oil by the manufacturer. Only install spacer sleeve for final frictional torque measurement (after determining shim "S3").

A - Torque gauge, commercially available, 0-600 Ncm

Scheme 275

B - Socket attachment, 36 mm A/F

Note. Use adapter 3/4 to 1/2 if necessary.

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

1. Tighten drive pinion nut until the following friction torque is obtained: FRICTION TORQUE SPECIFICATIONS - REAR FINAL DRIVE New bearings Used bearings (1) 200-250 Ncm 30-60 Ncm (1) Run at least 50 k
2. The final drive must be supported when tightening the nut (e.g. using universal transmission attachment V.A.G 1359/2 in conjunction with transmission jack V.A.G 1383 A).
3. Set adjustment ring of universal mandrel VW 385/1 Distance -a- = 60 mm
4. Set sliding adjustment ring. Distance b = 55 mm
5. Assemble universal mandrel as illustrated in (Scheme 286). Dial gauge extension VW 385/15 = 9 mm long
6. Set universal master gauge VW 385/30. Ro = 57.50 mm
7. Set dial gauge (3 mm measuring range) to "O" with 2 mm preload. NOTE: Before performing following measurements turn drive pinion at least five turns in both directions, so that the taper roller bearings settle. Otherwise a false reading will be obtained. Place end measuring plate VW 385/33 onto drive pinion head. Remove master gauge and insert measuring mandrel in the housing. The centering disc 385/3 faces toward cover for final drive Fit cover for final drive and tighten 4 bolts. Using the adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be turned by hand.

Scheme 281

1. Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then measure maximum deflection (return point). The measured value is dimension "e" (in red scale). Measurement in following example: "e" = 60 mm NOTE: Dimension "e" is required to determine thickness of shim "S3."
2. After removing universal mandrel, check once again whether the dial gauge reads "0" with 2 mm preload when master gauge VW 385/30 is in place - otherwise repeat the measurement.

Determining shim thickness "S3"

Formula

"S3" = "e" - "r"

e = Measured value

r = Deviation (tolerance): marked on ring gear in 1/100 mm

Example

1. Measured value "e" 60 mm Deviation "r" 0.42 mm = Thickness of shim "S3" 18 mm
2. Determine shim(s) from «S3 SHIM THICKNESS AVAILABILITY»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) table. The following shims are available for "S3" S3 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE Shim thickness (mm) (1) 0.95 1.20 1.45 1.00 1.25 1.50 1.05 1.30 1.55 1.10 1.35 1.15 1.40 (1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.
3. Remove universal mandrel.
4. Remove drive pinion and outer race of large taper roller bearing and install together with measured shims "S3" and spacer sleeve. See «REMOVING NUT FOR DRIVE PINION»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__removing-nut-for-drive-pinion) .
5. Install inner race of small taper roller bearing and tighten nut for drive pinion until specified friction torque is obtained. See «TIGHTENING NUT FOR DRIVE PINION AND MEASURING FRICTION TORQUE»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a__tightening-nut-for-drive-pinion-and) . NOTE: Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with a special oil by the manufacturer. Increase tightening torque slowly and check friction torque at regular intervals, if the specified friction torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.
6. Set to following frictional torques

FRICTIONAL TORQUE SPECIFICATIONS - REAR FINAL DRIVE

Checking dimension "r"

Scheme 282

1. Turn drive pinion at least 5 turns in both directions.
2. Insert universal mandrel and perform check measurement. If the shims have been correctly selected, the dial gauge should now show the value of "r" as marked on the ring gear, reading anti-clockwise in the red scale, within a tolerance of +/- 0.04 mm.
3. Fit cover for rear final drive and tighten 4 bolts.
4. After securing the nut for the drive pinion, measure the radial run-out at the flange for the driveshaft, and mark accordingly. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

Adjusting differential

ADJUSTMENT OVERVIEW lists the repairs after which the ring gear has to be adjusted.

1. VW382/10 extension pin
2. VW385/17 magnetic plate
3. VW387 dial gauge holder
4. VW388 measuring lever
5. VW521/4 locking sleeve
6. VW521/8 bushing
7. Dial gauge extension 30 mm
8. Dial gauge
9. Torque gauge 0-600 Ncm

Notes

Note. Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal." Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with a special oil by the manufacturer.

Setting preload of taper roller bearing for differential.

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

Scheme 283

Scheme 284

Scheme 285

1. Pull out drive flange oil seal with lever.
2. Remove differential taper roller bearing outer races and take out shims. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .
3. Press outer race of left-hand taper roller bearing for differential (housing side) with shim "S2" into housing. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) . To perform the measurement use a shim "S2*" with a thickness of 00 mm (one 0.80 mm shim and one 0.20 mm shim). NOTE: For measurement purposes a shim "S2" of 0 mm is initially inserted which will be designated "S2*" in the following. After determining the backlash "S2*" will be replaced by the correct "S2."
4. Knock in outer race of right-hand taper roller bearing for differential (final drive cover side) without shims. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) (install as far as the stop).
5. Insert differential into housing. The ring gear is positioned on the right side (cover side).
6. Fit cover and tighten bolts to 25 Nm.
7. Install special tools VW 521/4 and 521/8 onto housing side in differential housing.
8. Turn cover side of differential housing upward.
9. Turn differential 5 turns in both directions to settle the taper roller bearing.
10. Place measuring plate VW 385/17 onto differential.
11. Fit measuring tools. A - Dial gauge extension approx. 30 mm long B - Hexagon bolt M8 x 45
12. Place dial gauge extension on the center of the measuring plate VW 385/17.
13. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
14. Lift differential without turning; read off play on dial gauge and note. Measurement in following example: 0.50 mm

Note. If the measurement has to be repeated, the differential must again be turned 5 turns in each direction to settle the taper roller bearing.

Formula

"Stotal" = "S2*"+ measurement + bearing preload

Example

Inserted shim(s) "S2*" 1.00 mm

+ Measured value 0.50 mm

+ Bearing preload (constant) 0.30 mm

= Total shim thickness "Stotal"

for shims "S1" + "S2"

1.80 mm

Determining thickness of shim "S1*"

Note. The preliminary adjustment shim "S1*" will be replaced with the final shim "S1" after determining the backlash. The total shim thickness "Stotal" remains unchanged.

Formula

"S1*" = "Stotal" - "S2*"

Example

Total shim thickness "Stotal"

for shims "S1" + "S2"

1.80 mm

Inserted shim(s) "S2*" 1.00 mm

= Thickness of shim "S1*" 0.80 mm

1. Determine shim(s) from table in «DETERMINING THICKNESS OF SHIM "S1"»(/audi/a6/c5-1997-2001/remont/differentials-drive-axles/#5-spd-manual-transmission-01a) .

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

Scheme 286

1. Fit torque gauge 0-600 Ncm -A- onto differential.
2. Read off frictional torque.

Frictional torque specifications

FRICTIONAL TORQUE SPECIFICATIONS - REAR DIFFERENTIAL

Note. Differential tapered roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal." Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with a special oil by the manufacturer. If the final drive set (drive pinion and ring gear) is being re-adjusted, the adjustment of the drive pinion should be performed now, and the adjustment checked. See DRIVE PINION, ADJUSTING .

Adjusting backlash

Positioning ring gear in final drive housing.

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

Scheme 287

1. Insert differential in final drive housing, install cover and tighten all bolts to 25 Nm.
2. Turn differential 5 turns in both directions to settle the taper roller bearings.
3. Assemble measuring equipment.
4. Use dial gauge extension VW 382/10 (6 mm flat).
5. Set measuring lever VW 388 to dimension "a" = 60 mm.
6. Determine play between the teeth flanks as follows: Turn ring gear until it makes contact with a tooth flank (end of backlash travel). Set dial gauge to "0" with 1 mm preload.
7. Turn ring gear back until lying against an opposite tooth flank (backlash).
8. Read off backlash and note value.
9. Turn ring gear through 90° and repeat measurements a further 3 times.

Note. If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check installation, replace final drive set if necessary.

Example

1st measurement 0.28 mm

+ 2nd measurement 0.30 mm

+ 3rd measurement 0.30 mm

+ 4th measurement 0.28 mm

= Sum of measured values 1.16 mm

1. Result: The average backlash is 16 / 4 = 0.29 mm

Determining thickness of shim "S2"

Formula

"S2" = "S2*" - backlash + lift

Example

Inserted shim "S2*" 1.00 mm

Average backlash 0.29 mm

+ Lift (constant) 0.15 mm

= Thickness of shim "S2" 0.86 mm

1. Determine shim as accurately as possible from table.

The following shims are available for "S2"

S2 SHIM THICKNESS AVAILABILITY

Formula

"S1" = "Stotal" - "S2"

Example

Total shim thickness "Stotal" for "S1" + "S2" 1.80 mm

Thickness of shim "S2" 0.86 mm

= Thickness of shim "S1" 0.94 mm

1. Determine shim(s) as accurately as possible from table.

The following shims are available for "S1"

S1 SHIM THICKNESS AVAILABILITY

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

1. Turn differential 5 turns in both directions so that the taper roller bearings settle.
2. Measure backlash four times on circumference. Specifications: 0.12-0.22 mm

Scheme 288

Note. If the backlash lies outside the tolerance, the adjustment must be repeated, but the total shim thickness "Stotal" must remain unchanged. The individual measurements must not differ by more than 0.06 mm from each other.

See also:
• TOWING
• CHECKING FLUID LEVEL
• CLUTCHES - O1A, AWD
• CLUTCH MECHANISM, SERVICING
• SERVICE INTERVALS
• CODE LETTERS, ALLOCATION, RATIOS, CAPACITIES
• OIL LEVEL IN REAR FINAL DRIVE, CHECKING
• INPUT SHAFT BALL BEARING, MULTI-FUNCTION SENDER, INPUT SHAFT, DRIVE PINION, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING
• REVERSE GEAR WHEEL, REMOVING AND INSTALLING
• DRIVE PINION, ADJUSTING
• INPUT SHAFT, ADJUSTING
• DIFFERENTIAL, REMOVING AND INSTALLING
• DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
• INPUT SHAFT BALL BEARING AND MULTI-FUNCTION SENDER, REMOVING AND INSTALLING
• INPUT SHAFT, DRIVE PINION, HOLLOW SHAFT, SELECTOR RODS, TRANSMISSION COVER AND COVER WITH TORSEN DIFFERENTIAL, REMOVING AND INSTALLING
• SPEEDOMETER SENDER AND DRIVE WHEEL, REMOVING AND INSTALLING
• Breather installation position
• TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING
• OIL SEAL INSTALLATION POSITION
• INSTALLATION POSITION OF 5TH AND REVERSE GEAR SELECTOR FORK AND COUPLING PLATE FOR SELECTOR ROD
• DRIVE PINION AND RING GEAR, ADJUSTING
• TORSEN DIFFERENTIAL, SERVICING COVER AND REMOVING AND INSTALLING
• ADJUSTMENT OVERVIEW
• PULLING OUT NEEDLE BEARING
• PRESSING IN NEEDLE BEARING
• PRESSING OUT TORSEN DIFFERENTIAL
• INSTALLATION POSITION OF REAR NEEDLE BEARING
• PRESSING OFF BALL BEARING FROM TORSEN DIFFERENTIAL
• PRESSING BALL BEARING ONTO TORSEN DIFFERENTIAL
• REMOVING AND INSTALLING DRIVE FLANGE
• PRESSING OUT BALL BEARING FOR DRIVE FLANGE
• PRESSING IN BALL BEARING FOR DRIVE FLANGE
• REMOVING PLUG
• DRIVING IN SEAL
• PULLING OUT MOUNTING BUSH FOR 3RD AND 4TH GEAR SELECTOR ROD
• SECURING BOLT FOR NEEDLE BEARING
• INSTALLATION POSITION OF NEEDLE BEARING
• DRIVING IN OILING SLEEVE INTO INPUT SHAFT
• CHECKING SYNCHRO-RING FOR WEAR
• PRESSING OFF SYNCHRO-HUB FOR 3RD AND 4TH GEAR
• DETERMINING THICKNESS OF CIRCLIP
• INSTALLATION POSITION OF LOCKING COLLAR
• PRESSING OFF 5TH GEAR WHEEL
• PRESSING ON 5TH GEAR WHEEL
• PULLING OUT ROLLER SLEEVE
• INSTALLATION POSITION OF ROLLER SLEEVE
• PULLING OUT DOUBLE TAPER ROLLER BEARING OUTER RACE
• PRESSING IN DOUBLE TAPER ROLLER BEARING OUTER RACE
• PRESSING OFF DOUBLE TAPER ROLLER BEARING INNER RACE
• INSERTING SPRING IN SLIDING GEAR
• PRESSING OFF 1ST AND 2ND GEAR SYNCHRO-HUB
• PRESSING ON 1ST AND 2ND GEAR SYNCHRO-HUB
• INSTALLATION POSITION OF LOCKING COLLAR FOR 1ST AND 2ND GEAR
• PRESSING OFF 3RD GEAR WHEEL
• PRESSING ON 3RD GEAR WHEEL
• PRESSING OFF 4TH GEAR WHEEL
• PRESSING ON 4TH GEAR WHEEL
• PRESSING OFF 5TH GEAR AND REVERSE GEAR SYNCHRO-HUB
• PRESSING ON 5TH GEAR AND REVERSE GEAR SYNCHRO-HUB
• INSTALLATION POSITION OF OPERATING SLEEVE FOR 5TH AND REVERSE GEAR
• PRESSING OFF TAPER ROLLER BEARING INNER RACE
• PRESSING ON TAPER ROLLER BEARING INNER RACE
• PULLING OUT SECURING BUSH FOR TAPER ROLLER BEARING OUTER RACE
• PRESSING OUT TAPER ROLLER BEARING OUTER RACE
• ALLOCATION OF OPERATING SLEEVE TO REVERSE IDLER GEAR
• REPAIR INSTRUCTIONS, GENERAL
• SETUP OF DRIVE FLANGE WITH POLYGON BEARING
• REMOVING LEFT DRIVE FLANGE
• REMOVING AND INSTALLING CIRCLIP
• REMOVING SPACER RING
• INSTALLING SPACER RING
• DRIVE FLANGE ASSEMBLY
• SPEEDOMETER DRIVE WHEEL, REMOVING AND INSTALLING
• KNOCKING RIGHT TAPER ROLLER BEARING OUTER RACE OUT OF TRANSMISSION HOUSING
• PRESSING RIGHT TAPER ROLLER BEARING OUTER RACE INTO TRANSMISSION HOUSING
• PULLING OFF RIGHT TAPER ROLLER BEARING INNER RACE
• PRESSING ON RIGHT TAPER ROLLER BEARING INNER RACE
• HEAT RING GEAR TO APPROX. 100° C WHEN INSTALLING
• PULLING OFF LARGE TAPER ROLLER BEARING INNER RACE
• KNOCKING LEFT TAPER ROLLER BEARING OUTER RACE OUT OF COVER
• PRESSING LEFT TAPER ROLLER BEARING OUTER RACE INTO COVER
• INSTALLING SUN WHEELS AND PLANET PINIONS
• SHIMS, POSITION
• RING GEAR, ADJUSTING
• THICKNESS OF SHIM "S4" WHEN REPLACING TRANSMISSION COVER, REDETERMINING
• MEASURING BACKLASH
• DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S1" + "S2"
• DETERMINING THICKNESS OF SHIM "S3"
• DETERMINING THICKNESS OF SHIM"S2"
• DRIVESHAFT, SERVICING
• POSITION OF BREATHER SLEEVE
• KNOCKING OUTER RACE OF SMALL TAPER ROLLER BEARING OUT OF HOUSING
• PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING
• INSTALLING RING GEAR
• PULLING OFF INNER RACE FOR LARGE TAPER ROLLER BEARING
• PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING
• DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER
• REMOVING NUT FOR DRIVE PINION
• TIGHTENING NUT FOR DRIVE PINION AND MEASURING FRICTION TORQUE
• MEASURING FRICTION TORQUE
• SECURING DRIVE PINION NUT
• PULLING FLANGE FOR DRIVESHAFT OFF DRIVE PINION
• INSTALLING FLANGE
• DRIVING IN SEAL FOR FLANGE FOR DRIVESHAFT
• INSTALLING O-RING
• PRESSING ON SMALL TAPER ROLLER BEARING INNER RACE
• PULLING OUT OUTER RACE FOR SMALL TAPER ROLLER BEARING
• PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING
• DRIVING OUT OUTER RACE FOR LARGE TAPER ROLLER BEARING
• PULLING IN OUTER RACE FOR LARGE TAPER ROLLER BEARING
• PRESSING INNER RACE FOR LARGE TAPER ROLLER BEARING ONTO DRIVE PINION
• ADJUSTING BACKLASH