Home/Audi/A6/Audi A6 C5 facelift (2001-2004)/Repair manual/6 Spd. Manual Transmission - 01E/Installing

Contents

Wiring diagrams Section: 6 Spd. Manual Transmission - 01E

Final drive 01R is fitted in conjunction with manual transmission 01E (all wheel drive).

Transmission layout

Tow starting and towing vehicles

Transmission ratio

Example

Calculating

Repair instructions

O-rings, seals, gaskets

Sealants

Locking elements

Nuts, bolts

Bearings

Shims

Gears, synchro-hubs, inner races for sliding gears

Sliding gears

Synchronizer rings

Clutch mechanism

Bearing housing, Torsen differential and end cover, removing and installing

Gear cluster and selector shaft, removing and installing

5th and 6th gear, removing and installing

Input shaft, drive pinion, hollow shaft and internal selector mechanism from bearing plate, removing and installing

Removing

Pressing out drive flange

Pressing in drive flange

Driving in seal

Bearings for Torsen differential, servicing

Pressing off ball bearing for Torsen differential

Pressing on ball bearing for Torsen differential

Pulling off inner race for needle bearing for Torsen differential

Pulling out needle bearing for drive pinion/Torsen differential

Pressing in needle bearing for drive pinion/Torsen differential

End cover, servicing

Pulling cylinder roller bearing for input shaft out of end cover

Removing ball bearing for input shaft from end cover

Installing ball bearing for input shaft in end cover

Peening baffle plate in position when replacing ball bearing for input shaft

Peening baffle plate in position when replacing end cover

Pulling needle bearing for Torsen differential out from end cover

Bearing plate, servicing

Removing and installing ball sleeves for selector rods

Checking synchro-ring for wear

Pulling ball sleeve out of follower for reverse gear

Pressing cylinder roller bearing for input shaft into bearing plate

Measuring insertion depth of cylinder roller bearing for input shaft

Shim "S4," re-determining

Determining shim when replacing hollow shaft

Available shims for "S4"

Transmission housing, servicing

Pulling out seal for drive flange

Driving in seal for drive flange

Levering out seal for input shaft when transmission is dismantled

Removing seal for input shaft when transmission is not dismantled

Driving in seal for input shaft

Pulling out ball sleeve

Driving in ball sleeve

Pulling out seal for selector shaft

Driving in seal for selector shaft

Insertion depth of breather sleeve for transmissions without breather hose

Breather for transmission with breather hose

Pulling needle bearing out of transmission housing

Driving needle bearing into transmission housing

Insertion depth of needle bearing

Removing circlip

Driving out selector shaft

Driving in selector shaft

Inserting spring in sliding gear

Re-determining thickness of circlip

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

Driving spring pin into input shaft

Pulling out outer race for large taper roller bearing

Heating gearbox housing to insert the outer race for large taper roller bearing

Inserting outer race for large taper roller bearing in gearbox housing and pressing home

Pulling out needle bearing for flange shaft/drive pinion

Pressing off inner race for large taper roller bearing

Pressing on inner race for large taper roller bearing

Determining circlip for large taper roller bearing for drive pinion

Pressing off inner race of small taper roller bearing for drive pinion together with 1st speed sliding gear

Pressing on inner race for small taper roller bearing for drive pinion together with 1st speed sliding gear

Removing and installing circlip for synchro-hub and shim for 1st speed sliding gear

Pressing off 2nd speed sliding gear with synchro-hub for 1st and 2nd gear

Fitting 2nd speed sliding gear, pressing on synchro-hub for 1st and 2nd gear

Determining thickness of circlip for synchro-hub for 1st and 2nd gear

Pressing in outer race for small taper roller bearing

Installing

Speedometer sender -G22- and drive wheel for speedometer sender, removing and installing

Removing and installing speedometer sender -G22

Seal and grooved ball bearing for flange for driveshaft on transmission, replacing

Differential, removing and installing

Pulling inner race for small taper roller bearing out of housing

Pulling inner race for large taper roller bearing off housing

Pressing on inner race for small taper roller bearing

Installing ring gear

Driving outer race for large taper roller bearing out of cover

Drive pinion and ring gear, adjusting

Gear sets, adjusting and marking

Final drive set readjusting, recommended sequence

Shims, position

Drive pinion, adjusting

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

Determining thickness of shim "S3*"

Determining measurement "e"

Determining thickness of shim "S3"

The following shims are available for "S3"

Determining thickness of shim "S4"

The following shims are available for "S4"

Performing check measurement

Ring gear, adjusting

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

Determining thickness of shim "S1*"

Measuring backlash

Determining average backlash

Determining thickness of shim "S2"

The following shims are available for "S2"

Determining thickness of shim "S1"

The following shims are available for "S1"

Driveshaft, servicing

Procedure

Adjusting

Oil level in rear final drive, checking

Removing and installing drive flange

Position of breather sleeve

Pulling off inner race for large taper roller bearing

Adjusting sun wheels and planet pinions

Removing nut for drive pinion

Pulling flange for driveshaft off drive pinion

Pulling out outer race for small taper roller bearing

Driving out outer race for large taper roller bearing

Pressing inner race for large taper roller bearing off drive pinion

Pressing inner race for large taper roller bearing onto drive pinion

Pulling in outer race for large taper roller bearing

Installing O-ring

Driving in seal for flange for driveshaft

Installing flange

Securing drive pinion nut

Readjusting final drive set, recommended sequence

Determine thickness of shim "S3"

Adjusting backlash

All sections

Installing Audi A6 C5 facelift

6 Spd. Manual Transmission - 01E

Installing

Fill space between sealing and dust lips with sealing grease G52 128 A1.
Lightly oil outer circumference of seal.
Drive in seal for drive flange. Pressing-in depth (factory): 5.5 mm Pressing-in depth when re-installing a used drive flange (repairs): 6.5 mm
Install drive flange and drive axle.