Servicing - M/t (5-speed, 01a) Audi A6 C5

TRANSAXLE

This article applies to A6 models with the 01A with all wheel drive and 2.8L engine.

The AWD manual transmission 01A is installed in the Audi A6 as a 5-speed transmission.

Note. The code letters of the transmission are engraved on the lower part of the transmission cover and are also engraved on the vehicle data plates.

For identification locations on transaxle, see list below.

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

Scheme 1

Scheme 2

SERVICE INTERVALS

No oil changes are required.

CHECKING FLUID LEVEL

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

Depending on the version installed, use either 3357 triple square socket driver or a 17 mm to loosen the oil filler plug.

Remove oil filler plug. (Scheme 3) Oil level should be up to lower edge of filler hole. Add if necessary. Install filler plug and tighten to 18 ft. lbs. (25 N.m). When filling with NEW oil, remove plug (arrow). For recommended fluid, see RECOMMENDED FLUID. Top off oil to lower edge of filler hole. Install filler plug.

Scheme 3

RECOMMENDED FLUID

Manufacturer recommends API 75W-90, G50 synthetic gear oil. Part No. G 005 000 Size: 1 Liter.

FLUID CAPACITIES

TRANSMISSION REFILL CAPACITIES

BATTERY DISCONNECT PRECAUTIONS

After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock. Fully close power windows to window stop, then activate all power window switches ("up") for at least a second to activate automatic window raising/lowering. power windows.

If connector is disconnected from ECM or the battery is disconnected, all adaptation values in control module are erased. DTC memory content will remain intact however. If engine is started after this, a rough, uneven idle can result. In this case, engine must be allowed to run at idle for a few minutes or a longer road test must be performed until adaptation procedure has been completed.

Note. After battery has been disconnected, readiness code for Electronic Control Module (ECM) must be re-generated. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)

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

OnStar(R) Emergency Battery: Switching Off

1. In order to avoid unnecessary discharge of the emergency (back-up) battery, it must always be switched off prior to disconnecting the vehicle battery, and switched back on after the vehicle battery is reconnected.
2. Use VAS 5051 Vehicle Diagnosis, Testing and Information System in mode: "Guided Fault Finding". Enter appropriate model, equipment and model year information and press ">" to confirm.
3. After all control modules have been registered and DTC memories checked, press "Go to". Select "Function/Component Selection".
4. Select "01 - On Board Diagnostic (OBD) systems". Select "Telematic". Select "Functions -Telematic".
5. Select "J526 - Telephone/Telematic Ctrl. Module, service mode disc. battery".
6. If necessary, press ">" to advance.
7. To switch off emergency battery, select/press button 3 - "Service mode activating (no load on emergency battery)." Follow the tester's prompts.

OnStar(R) Emergency Battery: Switching On

Select/press button 3 - "Service mode activating (no load on emergency battery)". Follow the tester's prompts. Switch on emergency battery (Select/press button 1) "Service mode deactivating (normal operating condition)". Follow the tester's prompts.

Shift Mechanism: Adjusting

The following points are essential to ensure correct selector adjustment

1. Shift mechanism, operating and relay elements must be in proper condition.
2. Shift mechanism must move freely.
3. Transmission, clutch and clutch mechanism must be in proper condition.
4. Transmission in neutral.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. Shift cover is removed together with the cover for center console. Unscrew shift knob from shift lever. Slightly lift off cover for center console upward (arrows -A-). (Scheme 4) Pull cover slightly toward back (arrow -B-), then lift complete cover upward. (Scheme 4)
2. Remove noise insulation cover for shift mechanism housing (arrows). (Scheme 5)
3. Measure distance between body and rear push rod (in selector mechanism). (Scheme 6)
4. Specification: distance a = 1.614" (41 mm). If this is not the case, adjust dimension -a- as follows: Loosen push rod bolt (arrow). (Scheme 6) Rear push rod (in selector mechanism) should move freely in both directions on slide. Set to distance -a- by moving rear push rod (in selector mechanism). Tighten push rod bolt to 18 ft. lbs. (25 N.m).
5. Loosen bolt for shift rod -arrow A-. (Scheme 7) The connection, shift rod/shift mechanism must move freely.
6. Align shift lever as follows: Shift lever is vertical in direction of travel. Shift lever is slightly inclined toward rear. (Scheme 8) Hold shift lever in this position. Tighten bolt for shift rod to 18 ft. lbs. (25 N.m).

Shift Mechanism Adjustment: Checking

1. Shift lever must rest in 3rd/4th gear gate when transaxle is in Neutral. Operate clutch. Make sure all gears can be engaged properly.
2. Check operation of reverse gear lock. The gear shift should return by itself from the 5th/reverse gate into the 3rd/4th gate.
3. It must not be possible to shift directly into reverse gear from 5th gear.
4. It must only be possible to shift into reverse gear when shift lever starts in the neutral gate between 3rd/4th gears. NOTE: If only 5th gear and reverse gear cannot be engaged, the 5th and reverse gear locking unit must be checked and replaced if necessary. See «REMOVING & INSTALLING: GEAR LOCK FOR FIFTH & REVERSE GEAR»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a) .
5. If adjustment check is okay, attach covers and gear shift knob. If only 5th gear and reverse gear cannot be engaged. See «REMOVING & INSTALLING: GEAR LOCK FOR FIFTH & REVERSE GEAR»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a) .

Scheme 8

1. Remove heat shield (arrow 2) above right drive axle. (Scheme 9) Detach heat shield (arrow 1) above right drive axle and pivot downward. (Scheme 9)
2. Remove gear lock (arrow). (Scheme 10)

Scheme 9

Scheme 10

Scheme 11

1. Insert spring 1 into housing 2 and, while applying light pressure, turn spring to left until it locates in base of housing. (Scheme 11)
2. Insert bushing 3 onto spring so bent end of spring locates into groove properly. (Scheme 11)
3. Push bushing against spring and turn approx. one turn to left, until lug on bushing aligns with groove in housing.
4. Press lug of bushing into groove in housing onto stop.
5. Turn bushing to right and release. The bushing will spring into the correct position.
6. Installation position of bushing: Lug (arrow A) of bushing must always face away from groove in housing (arrow B). (Scheme 12)
7. Checking installation position: Turn bushing to left and release. The bushing should spring back into position; the lug must be against the stop, (direction indicated by arrow A). (Scheme 12)
8. Installation position of complete gear lock in transmission: The recess (arrow A) faces bolt (arrow B). (Scheme 13)

REMOVAL & INSTALLATION

AXLE SEALS

Note. This procedure is performed with transmission installed.

Note. A spacer ring is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm.

Scheme 12

Scheme 13

Scheme 14

1. Turn steering to full left lock stop. Remove heat shields (arrows -1- and -2-) above right-hand drive axle. (Scheme 14) If fitted, remove heat shield above left-hand drive axle. Disconnect drive axle from flanged shaft. Tie up drive shaft as high as possible. Do not damage paint on drive shaft. Place drip tray VAG 1306 underneath the transmission.
2. Remove left drive flange, to do so thread lower support of T10037 puller into housing (arrow). (Scheme 15)
3. Remove right drive flange, to do so thread lower support of T10037 puller into housing (arrow). (Scheme 16)
4. Always replace drive flange circlip. Clamp drive flange in vice, using soft jaws. Use new circlip -A- to press old circlip out of groove in drive flange. (Scheme 17)
5. Pull out drive flange oil seal with VW 681.
6. To assemble flange shaft with polygon (needle) bearings (Scheme 18) If polygon (needle) bearings are used, check them for cracks, excessive wear and damage. (Scheme 18)

Installation

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

1. Fill space between sealing and dust lips with multi-purpose grease. Lightly oil outer circumference of seal. Knock new right-hand drive flange oil seal in 5.5 mm (0.217 in.) below housing outer surface; do not cant seal when doing this. (Scheme 19) Knock drive flange in with drift VW 295. Bolt drive axle to drive flange.
2. Knock new left-hand drive flange oil seal in 5.5 mm (0.217 in.) below outer surface of cover using VW195; do not cant seal when doing this. (Scheme 19) Knock drive flange in with drift VW 295. Bolt drive axle to drive flange.
3. Check transmission oil level. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level).

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Unscrew lambda probe on right exhaust pipe with special tool 3337 and move clear to the side. Remove heat shields (arrows -1- and -2-) above right drive axle. (Scheme 20)(Scheme 21).
2. Unbolt front exhaust pipe with catalytic converter (right side) from exhaust manifold (3 nuts) -arrows-. (Scheme 21)
3. Remove heat shield for driveshaft from Torsen differential cover (arrows). (Scheme 22)
4. Unbolt driveshaft -1- from transmission and rest it on heat shield -2-. Remove driveshaft -1- from transmission and rest it on heat shield -2-. (Scheme 23) Secure driveshaft to fuel pipe bracket -3- with wire -arrows-.
5. Place VAG1306 drip tray underneath and drain transmission oil. Place VAG1306 drip tray underneath plug.
6. Remove circlip -A-. (Scheme 24) Screw an M8 bolt into thread of plug -B-. Pull out plug -B- using bolt. Oil will run out when removing cap -B-.
7. Open circlip and pull out drive flange. (Scheme 25)
8. Pull out drive flange oil seal with VW 681. (Scheme 26)

Scheme 22

1. Fill space between sealing lip and dust lip with a thin coat of G 052 128 A1 sealant. Lightly oil outer circumference of seal.
2. Knock new drive flange oil seal in 2 mm (0.079 in.) below housing outer surface; do not cant seal when doing this. Drive in drive flange seal 2 mm below outer housing surface, without canting. (Scheme 27)
3. Install drive flange. While inserting drive flange, fit circlip at the same time. (Scheme 25) The circlip must be seated in the base of the groove. Replace O-ring for plug. Fit plug and secure in position.
4. Install driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01A (AWD TRANSAXLE)»(ref-173866).
5. Top off and check transmission oil level. See «CHECKING FLUID LEVEL»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__checking-fluid-level).
6. Align exhaust system free of stress.

SHIFT MECHANISM

To identify shifter mechanism components. (Scheme 28)and (Scheme 29).

Scheme 23

Scheme 24

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

Scheme 25

1. Unscrew gear shift knob from gear shift. Cover on gear shift is removed together with cover for center console. Lift up cover for center console slightly, arrow -A-. Pull cover slightly toward the rear arrow -B- and then lift off the complete cover. (Scheme 4)
2. Remove noise insulating cover for gear shift housing -arrows-. (Scheme 5) Unscrew nuts securing gear shift housing -arrows-. (Scheme 30)
3. Separate exhaust system behind the catalytic converter, if necessary remove front exhaust system. Remove driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01A (AWD TRANSAXLE)»(ref-173866).
4. Remove selector rod arrow -A-. (Scheme 31) Unscrew hexagon socket head bolt on push rod -arrow B-. Remove front heat shield above exhaust system. Swing gear shift housing with selector rod and push rod down and remove.

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

1. Install in reverse order of removal, noting the following: Push selector rod on so that the securing bolt fits in the recess in the selector shaft.
2. Secure selector rod (arrow -A-) with bolt. (Scheme 31) Secure push rod to transmission (arrow -B-) with bolt.
3. Adjust gear selector mechanism. See «SHIFT MECHANISM»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__shift-mechanism).
4. Install and adjust driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01A (AWD TRANSAXLE)»(ref-173866).
5. Align exhaust system free of stress.

VEHICLE SPEED SENSOR

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

Raise and support vehicle. Pull connector off sender -A- (VSS). see scheme 32 Press retaining clip down, turn sensor sideways and pull out upward. Installing: When installing replace seal -B-. Insert sender and engage.

Scheme 26

VEHICLE SPEED SENSOR DRIVE WHEEL

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

Scheme 27

Scheme 28

1. Raise and support vehicle. Remove left drive flange and seal -B-. see scheme 33and «AXLE SEALS»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__axle-seals). Remove Vehicle Speed Sensor (VSS). See «VEHICLE SPEED SENSOR»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__vehicle-speed-sensor).
2. Press retaining clips in direction of arrows with a screwdriver. see scheme 34 Remove drive gear by prying out, alternating between sides.

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

1. Installation is the reverse order of removal, note the following: Installation position: The drive peg of the drive gear -A- faces to seal -B- and locates in the groove of the differential. see scheme 33 The retaining clips (arrows) lock in the circumferential groove in the differential. Always replace seal -B- and circlip -C-. See «AXLE SEALS»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a__axle-seals).
2. Drive in drive flange using VW295 needle bearing drift.
3. Check transmission oil level. Top off to lower edge of fill hole, if necessary. See «LUBRICATION»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a). Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/manual-trans/#servicing-mt-5-speed-01a).

Scheme 29

Scheme 30

Scheme 31

See also:
• RECOMMENDED FLUID
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• REMOVING & INSTALLING: GEAR LOCK FOR FIFTH & REVERSE GEAR
• BATTERY DISCONNECT PRECAUTIONS
• CHECKING FLUID LEVEL
• SHIFT MECHANISM
• AXLE SEALS
• VEHICLE SPEED SENSOR