6 Spd. Manual Transmission - 01e Audi S6 C5

Transmission, identification

The 6-speed manual transmission 01E (all wheel drive) is installed in Audi A6 vehicles in conjunction with the 2.7 liter bi-turbo engine, and in the Audi S6 (4.2 Liter V8). Allocation. See CODE LETTERS, ALLOCATION, RATIOS, AND CAPACITIES .

Location on transmission

1. Code letters and serial number (arrow -1-).
2. Manual transmission 01E (arrow -2-).

Scheme 1

Scheme 2

Additional data depends on manufacture.

Note. The transmission code letters are also included on the vehicle data stickers.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

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

Allocation. See CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES .

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 (Scheme 11).

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

Note. Arrows point in forward direction of travel.

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

VI - 6th gear

R - Reverse gear

A 1 - Front final drive

A 2 - Rear final drive

T - Speedometer drive, electronic

Scheme 10

Note. Arrows point in forward direction of travel.

Performance test on roller type test stand

The following must be noted when a vehicle with all wheel drive is to be driven onto a performance test stand

1. A four wheel test stand with four braked rollers must be used.

Brake test on the roller type test stand

The following must be noted when a vehicle with all wheel drive is to be driven onto a roller type test stand

1. A slow moving brake test stand (to 5,5 km/h) must be used. During this, no gear may be selected.

Tow starting and towing vehicles

See TOWING .

Transmission ratio

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

Example

Calculating

i G = 26 : 38 = 0.684

i A = 37 : 9 = 4.111

i ov = (26 : 38) x (37 : 9) = 0.684 x 4.111 = 2.813

Repair instructions

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.

Special tools

For a complete list of special tools used, see Special Tools Catalog.

1. When installing a replacement transmission or rear final drive, check oil level and top-up if necessary. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level) (transmission) and «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__oil-level-in-rear-final-drive) .
2. Vehicles with 2.7 ltr 195 kW engine: replacement transmissions contain an additional 0.3 ltr of oil for the pipes of the transmission oil cooling circuit. For this reason the transmission oil pipes and oil cooler must be drained when fitting a replacement transmission.
3. Capacities and specifications from. See «CODE LETTERS, ALLOCATION, RATIOS, AND CAPACITIES»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) and «CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Thoroughly clean all connections and the surrounding area before disconnecting.
5. When installing transmission, ensure dowel sleeves are correctly seated.

O-rings, seals, gaskets

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 a thin coating of sealing grease G 052 128 A1.
5. The open side of the oil seals faces toward the side with fluid filling.
6. When replacing oil seals, 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 oil seals. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level) (transmission) and «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__oil-level-in-rear-final-drive) .

Sealants

1. Thoroughly clean housing joint surfaces before applying sealing paste.
2. Apply sealing paste AMV 188 000 02 or AMV 188 001 02 evenly and not too thick.
3. Breather holes must remain free of sealing paste.

Locking elements

1. Do not overstretch circlips.
2. Always replace circlips which have been damaged or over-tensioned.
3. Circlips must be properly seated in the base of the groove.
4. Replace spring pins. Position: slit -A- should be in line with the line of force (arrow).

Scheme 11

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. Mark needle bearings of 1st to 6th speed sliding gears when removing, this ensures that when installing, the same installation position can be guaranteed.
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 or 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 installing, check 1st to 6th speed sliding gears for axial clearance of 0.15-0.35 mm and check that they rotate freely.

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. If the slave cylinder is removed with the hydraulic pipe attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.
3. Ensure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in several gradual 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.
5. Vehicles with V6 2.7 ltr bi-turbo and V8 4.2 Liter engines have an SAC pressure plate. On these vehicles an adjuster ring has to be reset. See «CLUTCH, SERVICING»(ref-233084-S24330382462006052400000) when replacing the clutch plate on its own.

Transmission, disassembling and assembling

Assembly sequence. See BEARING HOUSING, TORSEN DIFFERENTIAL, END COVER, INTERNAL SELECTOR MECHANISM, INPUT SHAFT, DRIVE PINION AND HOLLOW SHAFT, REMOVING AND INSTALLING (ASSEMBLY SEQUENCE) .

Note. The following list refers to (Scheme 14).

1. Bearing housing, Torsen differential and end cover Removing and installing. See «BEARING HOUSING, TORSEN DIFFERENTIAL AND END COVER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearing-housing-torsen-differential-and-end) .
2. Gear cluster and selector shaft Removing and installing. See «GEAR CLUSTER AND SELECTOR SHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__gear-cluster-and-selector-shaft-removing) .
3. Differential Removing and installing. See «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__differential-removing-and-installing) .

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

Note. The following list refers to (Scheme 15).

1. Bearing housing Disassembling and assembling. See «BEARING HOUSING, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearing-housing-disassembling-and-assembling).
2. Bolt, 25 Nm Qty. 6
3. Dished spring Installation position: larger diameter (concave side) faces shims
4. Shim Qty. 2 or 3 Re-determining shims. (Scheme 73)and (Scheme 74).
5. Oil collector Disassembling and assembling. (Scheme 69) Removing. (Scheme 23) Installing. (Scheme 71)
6. Multi-point socket head bolt, 150 Nm Removing. (Scheme 27)
7. 2nd inner race for taper roller bearing for input shaft Removing. (Scheme 29) Installing. (Scheme 67)
8. Spring
9. Torsen differential Can be serviced only by manufacturer Servicing bearings for Torsen differential. See «BEARINGS FOR TORSEN DIFFERENTIAL, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearings-for-torsen-differential-servicing).
10. Bolt, 25 Nm Qty. 5
11. End cover Servicing. See «BEARINGS FOR TORSEN DIFFERENTIAL, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearings-for-torsen-differential-servicing).
12. Gasket Replace
13. Dowel sleeve Qty. 2
14. Gear cluster Removing and installing. See «GEAR CLUSTER AND SELECTOR SHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__gear-cluster-and-selector-shaft-removing)
15. Oil drain plug - 40 Nm
16. Magnet Qty. 2 Clean
17. Support plate Installation position: lugs face magnets
18. Bolt, 25 Nm Qty. 2

Gear cluster and selector shaft, removing and installing

Note. The following list refers to (Scheme 16).

1. 5th and 6th gear Gear cluster remains flanged to transmission housing Removing and installing. See «5TH AND 6TH GEAR, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__5th-and-6th-gear-removing-and).
2. Bearing plate complete Removing and installing input shaft, drive pinion, hollow shaft and internal selector mechanism. See «INPUT SHAFT, DRIVE PINION, HOLLOW SHAFT AND INTERNAL SELECTOR MECHANISM FROM BEARING PLATE, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__input-shaft-drive-pinion-hollow-shaft).
3. Bolt - 25 Nm Qty. 3 Apply sealing paste AMV 188 000 02 when installing
4. Cover for selector shaft Removing. (Scheme 25) Installing. (Scheme 72)
5. Selector shaft complete Disassembling and assembling. See «SELECTOR SHAFT (COMPLETE), DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__selector-shaft-complete-disassembling-and-assembling).
6. Locking bolt For aluminium bolt: 50 Nm For steel bolt: 70 Nm Mark installation positions of aluminium bolts and steel bolts; do not interchange
7. Transmission housing Servicing. See «TRANSMISSION HOUSING, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__transmission-housing-servicing).
8. Oil filler plug, 40 Nm
9. Differential Removing and installing. See «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__differential-removing-and-installing).
10. Oil drain plug, 40 Nm
11. Dowel sleeves Qty. 2
12. Bolt, 25 Nm Qty. 12

5th and 6th gear, removing and installing

Note. The following list refers to (Scheme 17).

1. 1st inner race for taper roller bearing for input shaft Pulling off. (Scheme 29) Installing. (Scheme 65)
2. Needle bearing for 5th gear
3. Inner race for 5th speed sliding gear Pulling off. (Scheme 30) Driving on. (Scheme 64)
4. 5th speed sliding gear Pulling off. (Scheme 30) Installing. (Scheme 62)
5. Roll pin Pressing out. (Scheme 32) Pressing in. (Scheme 59)
6. Follower Only replace complete with selector rod for 5th and 6th gear -8- Pulling off. (Scheme 33) Fitting. (Scheme 58)
7. Selector fork for 5th and 6th gear Can be replaced individually
8. Selector rod for 5th and 6th gear Only replace complete with follower -6- Removing. (Scheme 34) Installing. (Scheme 50)
9. Locking collar, synchro ring, synchro-hub for 5th and 6th gear Removing. (Scheme 34) Installing. (Scheme 56)
10. Circlip Re-determining. (Scheme 63)
11. 5th speed gear Pulling off. (Scheme 31) Pressing on. (Scheme 62)
12. 6th speed sliding gear Pull off together with synchro-hub and inner race for 5th gear. (Scheme 35)
13. Needle bearing for 6th gear
14. Thrust washer for needle bearing for 6th gear Installation position: grooves face circlip, smooth face contact surface towards needle bearing
15. Circlip
16. Inner race for cylinder roller bearing Take off by hand. (Scheme 38)
17. Shim Re-determine thickness. See «5TH SPEED GEAR SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
18. Spacer sleeve Length 39.6 mm
19. 6th speed gear To press off, remove bearing plate. (Scheme 38) Pressing off. (Scheme 43) Pressing on. See «INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing).

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

Note. The following list refers to (Scheme 18).

1. Bearing plate Servicing. See «BEARING PLATE, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearing-plate-servicing).
2. Selector rod for 5th and 6th gear Only replace complete with follower for 5th and 6th gear. (Scheme 103)
3. Follower for reverse gear Pulling out ball sleeve. See «PULLING BALL SLEEVE OUT OF FOLLOWER FOR REVERSE GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-ball-sleeve-out-of-follower). Driving in ball sleeve. See «DRIVING BALL SLEEVE FLUSH INTO FOLLOWER FOR REVERSE GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
4. Selector fork for 3rd and 4th gear Can be replaced individually Installation position: rib towards follower
5. Selector rod for 3rd and 4th gear Only replace complete with follower for 3rd and 4th gear
6. Input shaft Disassembling and assembling. See «INPUT SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__input-shaft-disassembling-and-assembling).
7. Follower for 1st and 2nd gear Can be replaced individually
8. Circlip Qty. 2
9. Selector rod for 1st and 2nd gear Only replace together with selector fork for 1st and 2nd gear (secured together by means of a pin)
10. Hollow shaft Disassembling and assembling. See «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__drive-pinion-and-hollow-shaft-disassembling).
11. Drive pinion Disassembling and assembling. See «DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__drive-pinion-and-hollow-shaft-disassembling).
12. Locking bolts Qty. 4 For aluminium bolt: 50 Nm For steel bolt: 70 Nm Mark installation positions of aluminium bolts and steel bolts; do not interchange

Special tools, testers and auxiliary items required

1. Engine and transmission support VW 540
2. Drip tray VAG 1306
3. Multi-purpose tool 771/1 with attachments 771/15, 771/37 and stud M8/M10
4. Two-arm puller e.g. Kukko 20/10 with 200 mm long hooks
5. Mandrel 2064
6. Clamping sleeve 3116
7. Thrust piece 3118
8. Drift 3121
9. Internal puller 3275
10. Pressing tool 3276
11. Thrust plate VW 402
12. Press tool VW 407
13. Press tool VW 412
14. Tube VW 415a
15. Thrust plate VW 447h
16. Thrust pad VW 454
17. Extractor lever VW 681
18. Extension piece 30-23
19. Drift sleeve 30-100
20. Support bridge 30-211A
21. Press tool 40-21
22. Depth gauge

Removing

1. Secure transmission on engine and transmission support VW 540.
2. Place drip tray VAG 1306 underneath and drain transmission oil (2 oil drain plugs).
3. Remove release bearing, clutch release lever and guide sleeve. See «REMOVING CLUTCH RELEASE LEVER»(ref-233084-S04935430772006053000000) .
4. Remove bearing housing (arrow) and pull off.

A-M8/M10 stud

When pulling off, the bearing housing is pressed slightly off the end cover by the spring -A-.

1. When removing the bearing housing, note position of spring plate -C-: Outer diameter (concave side) towards shims
2. Remove shims -B-, note thickness re-determine if necessary. (Scheme 74)
3. Pull Torsen differential out of end cover.
4. Pull oil collector out of end cover (arrow) until it moves freely.
5. Swing oil collector (arrow) down and guide out through hole in end cover.
6. Remove oil collector.
7. Remove locking bolts -A- for selector shaft from transmission housing.
8. Mark installation positions of aluminium bolts and steel bolts; do not interchange.
9. Remove 3 bolts -B- for cover for selector shaft, take off cover.
10. Pull out selector shaft.
11. Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates (arrows).
12. Loosen and unscrew multi-point socket head bolt (arrow -B-) in input shaft through hole (arrow -A-) in end cover. (Scheme 27)
13. Remove 2 securing bolts (arrow -C-) for end cover for transmission at supporting plate for needle bearings -arrow D-.
14. Take out supporting plate.
15. Remove the 2 magnets (arrows -A-) and clean. (Scheme 28)
16. Loosen the 5 bolts (arrows -B-) for securing end cover for transmission and remove.
17. Pull 2nd inner race for ball bearing for input shaft from input shaft.

A - Washer (Scheme 29)

Scheme 12

Note. The internal extractor 3275 grips the circumferential groove of the inner race (arrow) during the pulling operation. (Scheme 30)

1. Take off end cover together with end cover/bearing plate gasket.
2. Pull dowel sleeves out of bearing plate.
3. Pull off 5th speed sliding gear with spring together with 1st inner race -A- for ball bearing for input shaft. (Scheme 30) B - Two arm puller, e.g. Kukko 20/10
4. Take off 5th gear synchro-ring.
5. Take off circlip for 5th speed gear.
6. Pull off 5th speed gear, to do this, block hollow shaft by engaging 2 gears. (Scheme 26)

Note. Use only hex bolt of tensioning sleeve 3116, length 50 mm.

C - Two arm puller, e.g. Kukko 20/10 with 200 mm long puller arms

1. Remove shim -B- for 5th speed gear, note thickness and re-determine if necessary. See «5TH SPEED GEAR SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
2. Take off spacer sleeve -A-.
3. Press out roll pin -A- for selector fork for 5th and 6th gear.
4. Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (until stop is felt).

Note. Do not drive out roll pin, otherwise selector rod bearing will be damaged.

Scheme 13

1. Mark installation position (arrow -3-) of locking collar for 5th and 6th gear (arrow -1-) and synchro-hub -A- (paired).
2. Pull follower together with selector fork and locking collar off selector rod.
3. Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th speed gears and inner race for 5th speed sliding gear. A - Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks
4. Unscrew selector rod locking bolts. A - 1st and 2nd gear B - 3rd and 4th gear C - 5th and 6th gear D - Reverse gear
5. Mark fitting locations of aluminium and steel bolts. (Bolts must not be interchanged when installing.)
6. Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
7. Secure drive pinion relative to hollow shaft e.g. hose tie, to prevent it falling out.
8. Separate bearing plate with input shaft, with drive pinion and hollow shaft and with inner selector mechanism from transmission housing.
9. Remove circlip from selector rod for 1st and 2nd gear and take off follower -A-.
10. Pull out selector rod -B- for 5th and 6th gear.
11. Remove follower -C- for reverse gear.
12. Pull thrust washer (arrow -A-) for needle bearing for 6th gear off shaft.
13. Use right-angled circlip pliers to remove circlip (arrow -B-) for inner race for cylinder roller bearing.
14. Take out inner race (arrow -C-) for cylinder roller bearing (not a press fit).
15. Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing plate.
16. Unscrew hex bolt -D-, take off spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse idler gear. (Scheme 40)
17. Take out spring, synchro-ring and reverse idler gear.
18. Take off relay lever for reverse gear.

Note. Drive pinion and hollow shaft can be removed complete if the 6th speed gear can be easily levered off. If it is necessary to press off the 6th speed gear, the drive pinion must be pulled out of the hollow shaft.

1. Remove drive pinion circlip.
2. Pull drive pinion out of hollow shaft -D-, when doing this catch the taper rollers -A- (Qty. 23). (Scheme 41)
3. Take off corrugated spring -B- and needle ring -C-.

Note. Carefully protect bearings from dirt, clean if necessary.

Scheme 14

1. Check bearing to ensure it is complete. (Scheme 42) Flange ring (tapered contact surface to tapered rollers) Tapered rollers (Qty. 23) with larger diameter facing towards drive pinion head Support ring (tapered contact surface to tapered rollers) Corrugated spring Circlip for tapered roller bearing for drive pinion
2. Press off 6th speed gear.

Note. Because of the type of fit, it may be possible to press gear off easily.

1. Take hollow shaft or drive pinion and hollow shaft with selector rod and selector fork for 1st and 2nd gear out of the bearing plate.

Scheme 15

1. Fit hollow shaft with selector fork and selector for 1st and 2nd gear (without follower) into bearing plate.
2. Heat 6th gear to approx. 120 ° C and fit on. Installation position: shoulder towards taper roller bearing
3. Press onto stop; ensure there is no play.
4. Grease drive pinion/hollow shaft taper roller bearing with multi-purpose grease before inserting. A - Flange ring, tapered rollers (Qty. 23), and support ring. (Scheme 45) B - Corrugated spring C - Needle ring D - Hollow shaft
5. Oil needle bearing well.
6. Insert drive pinion into hollow shaft and secure with hose clip to prevent it slipping out.
7. Fit relay lever -A- for reverse gear onto bolt for relay lever. Watch position of pin when doing this (limits relay lever travel to synchro-ring). (Scheme 46)
8. Insert sliding gear -B- and engage relay lever with groove on sliding gear.
9. Insert synchro-ring -C-. Installation position: position flat on circumference of synchro-ring towards input shaft (not as yet fitted) (arrow-1-). (Scheme 46)
10. Insert spring. Installation position: hook single angled end into recess on synchro-ring (arrow -2-). Turn double angled end anti-clockwise and hook into opening in bearing plate (arrow -3-)
11. Insert shaft -C-. (Scheme 47)
12. Fit retaining plate -A-. Installation position: chamfers of holes for locking pins of the synchro-ring face bearing plate
13. Insert spring clasp -B- into locking pins of the synchro-ring. (Scheme 47)
14. Replace self-locking nut -D- and tighten to 25 Nm.
15. Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into the bearing plate. (Scheme 48) Selector fork installation position: rib towards follower. See INSTALLATION POSITION.
16. Slide inner race (arrow -C-) for cylinder roller bearing onto main shaft at flange for end cover (clearance fit). (Scheme 49)
17. Fit circlip (arrow -B-) using right-angled circlip pliers.
18. Engage recess in follower for reverse gear with the free end of relay lever (arrow -A-). (Scheme 50)
19. Slide selector rod for 5th and 6th through follower for reverse gear in direction of (arrow-B-).
20. Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips. (Scheme 51)
21. Oil all bearings of input shaft and drive pinion/hollow shaft in transmission housing and bearing flange as well as the selector rods with gear oil.
22. Lever used seal for input shaft carefully out of transmission housing with VW 681.
23. Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 000 02.
24. Insert complete bearing plate into transmission housing.

Note. When inserting the complete bearing plate, ensure that the selector rods align with their mounting points.

1. Drive in 2 dowel sleeves for bearing flange/transmission housing.
2. Tighten 12 bolts using diagonal sequence to 25 Nm.
3. Screw in locking bolts for selector rods. (Scheme 53) A - 1st and 2nd gear B - 3rd and 4th gear C - 5th and 6th gear D - Reverse gear
4. Aluminium and steel bolts must not be interchanged when installing. Tightening torques: for aluminium locking bolts = 50 Nm, and for steel locking bolts = 70 Nm
5. Fit thrust washer (arrow -A-) for needle bearing for 6th speed gear. (Scheme 54) Installation position: shoulder towards circlip (arrow -B-), smooth contact surface to shaft end.
6. Oil needle bearing for 6th speed sliding gear with gear oil and fit.
7. Slide on 6th speed sliding gear with spring and synchroring. Synchro-ring installation position: the lugs of the synchroring engage into the recesses below in the sliding gear
8. Support input shaft with support bridge 30-211 A.

Installation position of synchro-hub for 5th and 6th gear

Scheme 16

1. Side with projecting face (arrow -1-) faces shaft end. (Scheme 56)
2. The oil drilling of the input shaft (arrow -2-) and the oil groove of the synchro-hub (arrow -3-) are in line. (Scheme 56)

1. Heat synchro-hub for 5th and 6th gear to approx. 100 ° C, fit and drive on; ensure there is no play.
2. Check 6th speed sliding gear for axial play.
3. Line up markings (arrow -3-) on paired synchro-hub -A- and locking collar for 5th and 6th gear (arrow -1-). (Scheme 58)
4. Fit locking collar (arrow -1-) with selector fork (arrow -2-) onto synchro-hub -A- as well as follower for 5th and 6th gear -B- onto selector rod -C- at the same time.

Note. Selector fork rib (arrow -2-) must face towards shaft end. (Scheme 58) When sliding follower onto selector rod for 5th and 6th gear remember holes for roll pin.

1. Press in roll pin -A- flush.

Note. Do not drive in roll pin, otherwise selector rod mounting will be damaged.

Re-determining shim for 5th speed gear

1. Fit spacer sleeve -A- (length 39.6 mm) onto hollow shaft. (Scheme 60)
2. When fitting circlip, push in direction of arrow onto stop.
3. Measure distance between sleeve and fitted circlip with depth gauge -B-.
4. Determine shim from «5TH SPEED GEAR SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table. Part numbers, see parts catalog.

The following shims are available

5TH SPEED GEAR SHIM THICKNESS AVAILABILITY

1. Fit shim selected (arrow) onto hollow shaft.
2. Heat 5th speed gear to approx. 120 °C, fit and drive onto stop free of play. Installation position: shoulder towards spacer sleeve

Re-determining circlip for 5th speed gear

Scheme 17

1. Determine the thickest circlip that can still just be fitted.
2. Determine circlip from «5TH SPEED GEAR CIRCLIP AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table. Part numbers, see parts catalog.

The following circlips are available

5TH SPEED GEAR CIRCLIP AVAILABILITY

1. Fit circlip.
2. Drive on inner race for 5th speed sliding gear free of axial play.
3. Oil needle bearing with gear oil and fit.
4. Place synchro-ring for 5th gear in locking collar.
5. Slide on 5th speed sliding gear with spring.
6. Heat 1st inner race for ball bearing for input shaft to approx. 100 ° C, fit onto input shaft and drive onto stop; ensure there is no play.
7. Check 5th speed sliding gear for axial clearance.
8. Permissible axial clearance: 0.15-0.35 mm
9. Insert dowel sleeves into bearing plate.
10. Fit new gasket for end cover.
11. Fit end cover and insert securing bolts (arrows -B-). (Scheme 66)

Note. Do not tighten bolts.

Scheme 18

1. Clean the two magnets (arrows -A-) and insert. (Scheme 66)
2. Fit support plate and tighten hand tight. Installation position: Lugs towards magnets
3. Tighten bolts for end cover using diagonal sequence.
4. Oil 2nd inner race and with ball contact surface facing towards input shaft ball bearing, drive onto input shaft through hole in end cover.
5. Remove support bridge 30-211 A.
6. Lock input shaft by engaging 2 gears (for example, reverse and 2nd gear), do this by moving two selector plates (arrows). (Scheme 68)
7. Tighten multi-point socket head bolt to 150 Nm.
8. Unclip cover -3- for oil collector from oil collector -1- at longer end with a screwdriver and remove magnet -2-. (Scheme 69) 4 - O-ring 5 - Positioning segment
9. Clean oil collector.
10. Assemble oil collector.
11. Guide oil collector from interior of end cover with support arm leading through the hole of the end cover (arrow), until the O-ring can be fitted from outside onto the oil collector.
12. Lightly oil new O-ring and fit.
13. Insert oil tube of oil collector into input shaft.
14. Turn oil collector until the positioning segment is located in the machined recess of the end cover (arrow).
15. Press in oil collector onto stop.
16. Slide assembly sleeve, Part No. 01E 311 120, onto selector shaft.
17. Check neutral position of followers. Selector gates must align.
18. Install complete selector shaft.
19. Screw locking bolts -A- for selector shaft into transmission housing.
20. Aluminium and steel bolts must not be interchanged when installing. Tightening torques: for aluminium locking bolts = 50 Nm, and for steel locking bolts = 70 Nm. (Scheme 72)
21. Lightly oil new O-ring for cover for selector shaft and fit.
22. Fit cover for selector shaft.
23. Apply sealing paste AMV 188 000 02 to bolts -B- (Qty. 3) before installing and tighten.
24. Slide Torsen differential onto splines of hollow shaft.
25. Press Torsen differential in direction of arrow, and measure distance between top edge of the bolted end cover and front edge of outer race of ball bearing for Torsen differential. (Scheme 73)
26. Determine required shim(s) from (Scheme 74).

Scheme 19

Scheme 20

1. Insert spring plate -C- into bearing housing. (Scheme 75) Installation position: larger diameter (concave side) towards the shims.
2. Fit shims -B- as determined in table. (Scheme 75)
3. Fit spring -A- to end of drive flange.
4. Lightly oil new O-ring for bearing housing and fit.
5. Oil small needle bearing in drive pinion.
6. Insert complete bearing housing and pull home evenly.
7. Tighten bearing housing using diagonal sequence.
8. Fill new seal for drive axle between sealing lip and dust lip with sealing grease G52 128 A1.
9. Pull a thin protective hose tightly onto splines of input shaft.
10. Drive on seal for input shaft. Pressing-in depth (factory): 3.5 mm Pressing in depth (repairs): 4.5 mm
11. Remove protective hose.
12. Install release bearing, clutch release lever and guide sleeve from. See «CLUTCH RELEASE MECHANISM, SERVICING»(ref-233084-S15987805642006052400000).
13. Check that transmission can be shifted through all gears.
14. Fit connecting rod.
15. Check oil level in transmission. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level).

Bearing housing, disassembling and assembling

Special tools, testers and auxiliary items required

1. Adapter VW 295a
2. Thrust plate VW 401
3. Thrust plate VW 402
4. Press tool VW 407
5. Press tool VW 412
6. Tube VW 415a
7. Tube VW 416b
8. Press tool VW 433
9. Thrust pad VW 454
10. Support rails VW 457
11. Extractor lever VW 681
12. Punch 2005
13. Thrust pad 2007
14. Shim, Part No. 016 311 391 B

Note. The following list refers to (Scheme 77).

1. Drive flange Pressing out. See «PRESSING OUT DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-out-drive-flange) . Pressing in. See «PRESSING IN DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-in-drive-flange) .
2. Balance weight Pressing off. See «PRESSING OFF BALANCE WEIGHT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Pressing on. See «PRESSING ON BALANCE WEIGHT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
3. Seal Pulling out. See «PULLING OUT SEAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Preparing for installation. See «PREPARING SEAL FOR INSTALLATION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__preparing-seal-for-installation) . Driving in. See «DRIVING IN SEAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal) .
4. Bearing housing
5. O-ring Always replace Lightly oil before installing
6. Ball bearing for drive flange Pressing off. See «PRESSING OUT BALL BEARING FOR DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Pressing in. See «PRESSING IN BALL BEARING FOR DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
7. Circlip

Pressing out drive flange

1. Before pressing out drive flange remove circlip.

Pressing in drive flange

1. Before pressing in drive flange, press on balance weight. See «PRESSING ON BALANCE WEIGHT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
2. Fit circlip.

Scheme 21

Scheme 22

Note. Note position of holes.

Scheme 23

Preparing seal for installation

A - Shim Part No. 016 311 391 B (1.7 mm thick)

B - Seal

Scheme 24

1. Fill space between sealing and dust lips with sealing grease G52 128 A1.
2. Fit shim and seal onto tool one after the other. Installation position: open side of seal towards bearing housing

Driving in seal

1. Remove shim.

Scheme 25

Scheme 26

Bearings for Torsen differential, servicing

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Press tool VW 407
4. Press tool VW 412
5. Press tool VW 432
6. Thrust plate VW 447h
7. Clamping sleeve 3116
8. Thrust piece 3118
9. Separating device 22-115 mm, e.g. Kukko 17/2
10. Internal puller 30-37 mm, e.g. Kukko 21/5
11. Counter support e.g. Kukko 22/1

Note. The following list refers to (Scheme 87).

1. Ball bearing for Torsen differential Pressing off. See «PRESSING OFF BALL BEARING FOR TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-off-ball-bearing-for-torsen) . Pressing on. See «PRESSING ON BALL BEARING FOR TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-on-ball-bearing-for-torsen) .
2. Torsen differential Can only be serviced by manufacture
3. Inner race for needle bearing for Torsen differential Pulling off. See «PULLING OFF INNER RACE FOR NEEDLE BEARING FOR TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-off-inner-race-for-needle) . Pressing on. See «PRESSING ON INNER RACE FOR NEEDLE BEARING FOR TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Needle bearing for drive pinion/Torsen differential Pulling out. See «PULLING OUT NEEDLE BEARING FOR DRIVE PINION/TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-needle-bearing-for-drive) . Pressing in. See «PRESSING IN NEEDLE BEARING FOR DRIVE PINION/TORSEN DIFFERENTIAL»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-in-needle-bearing-for-drive) .

Note. The shims for the Torsen differential must be re-determined after replacing the following parts. (Scheme 74): End cover Inner race for needle bearing Torsen differential Ball bearing for Torsen differential

Pressing off ball bearing for Torsen differential

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

Scheme 27

Pressing on ball bearing for Torsen differential

1. Press piece 3118 with shoulder towards press tool VW 412

Pulling off inner race for needle bearing for Torsen differential

A - Inner race

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

Scheme 28

Scheme 29

Pulling out needle bearing for drive pinion/Torsen differential

A - Internal puller 30-37 mm, e.g. Kukko 21/5

B - Counter support, e.g. Kukko 22/1

Scheme 30

Pressing in needle bearing for drive pinion/Torsen differential

1. Press in needle bearing flush.

End cover, servicing

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Press tool VW 407
3. Press tool VW 412
4. Tube VW 415a
5. Spacer sleeve VW 472/2
6. Thrust ring 2006A
7. Internal puller 37-46 mm (e.g. Kukko 21/6)
8. Internal puller 46-58 mm (e.g. Kukko 21/7)
9. Counter support (e.g. Kukko 22/2)

Note. The following list refers to (Scheme 94).

1. End cover If replaced: Re-determine thickness of circlip -5- Re-determine shims for Torsen differential. (Scheme 73)and (Scheme 74).
2. Oil drain plug, 40 Nm
3. Cylinder roller bearing for input shaft Pulling out. See «PULLING CYLINDER ROLLER BEARING FOR INPUT SHAFT OUT OF END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-cylinder-roller-bearing-for-input). Pressing in flush. See «PRESSING CYLINDER ROLLER BEARING FOR INPUT SHAFT FLUSH INTO END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-cylinder-roller-bearing-for-input).
4. Ball bearing for input shaft Removing. See «REMOVING BALL BEARING FOR INPUT SHAFT FROM END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-ball-bearing-for-input-shaft). Installing. See «INSTALLING BALL BEARING FOR INPUT SHAFT IN END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-ball-bearing-for-input-shaft). If replaced, re-determine thickness of circlip -5
5. Circlip Re-determine thickness. See «BALL BEARING FOR INPUT SHAFT CIRCLIP AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). Installing. See «INSTALLING BALL BEARING FOR INPUT SHAFT IN END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-ball-bearing-for-input-shaft).
6. Baffle plate Replace Removing. See «REMOVING BALL BEARING FOR INPUT SHAFT FROM END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-ball-bearing-for-input-shaft). Installing and peening in position when replacing ball bearing for input shaft. See «PEENING BAFFLE PLATE IN POSITION WHEN REPLACING BALL BEARING FOR INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__peening-baffle-plate-in-position-when). Installing and peening in position when replacing end cover. See «PEENING BAFFLE PLATE IN POSITION WHEN REPLACING END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__peening-baffle-plate-in-position-when).
7. Needle bearing for Torsen differential Pulling out. See «PULLING NEEDLE BEARING FOR TORSEN DIFFERENTIAL OUT FROM END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-needle-bearing-for-torsen-differential). Driving in. See «DRIVING NEEDLE BEARING FOR TORSEN DIFFERENTIAL FLUSH INTO END COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-needle-bearing-for-torsen-differential).

Pulling cylinder roller bearing for input shaft out of end cover

A - Internal puller 37-46 mm, e.g. Kukko 21/6

B - Spindle from counter support Kukko 22/2

Scheme 31

Pressing cylinder roller bearing for input shaft flush into end cover

1. Tube VW 415a with shoulder towards press tool VW 412

Removing ball bearing for input shaft from end cover

1. Position screwdriver as illustrated, drive into baffle plate (arrow) and lever out.
2. Remove circlip.
3. Take out bearing, remove peening indentations if necessary.

Installing ball bearing for input shaft in end cover

Installation position of circlip

1. Ends of circlip (arrows), point towards needle bearing. (Scheme 98)

Note. The thickness of the circlip must be re-determined if the bearing or the end cover are replaced.

1. Determining circlip for ball bearing for input shaft
2. Press ball bearing outer race onto stop.
3. Determine the thickest circlip that can still just be fitted.
4. Axial play: max. 0.08 mm
5. Determine circlip from «BALL BEARING FOR INPUT SHAFT CIRCLIP AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table. Part numbers.

The following circlips are available

BALL BEARING FOR INPUT SHAFT CIRCLIP AVAILABILITY

1. Fit circlip.

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

1. Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen in position.
2. Insert baffle plate.
3. First peen at points marked with -arrows 1-. (Scheme 99)
4. Then peen at points marked with arrows 2- at distance -a- from first position. Dimension a = 5 mm
5. Observe position and diameter of peening positions: Dimension b = 2 mm Dimension c = 3 mm

Peening baffle plate in position when replacing end cover

1. Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen in position.
2. Insert baffle plate.
3. Peen in first peening point (arrow) at distance -d- from the center line of the two shafts. (Scheme 100) Dimension d = 10 mm
4. Observe position and diameter of peening positions. Dimension b = 2 mm Dimension c = 3 mm
5. Peen in second and third peening points in same manner at distance -a-. (Scheme 100) Dimension a = 70 mm

Pulling needle bearing for Torsen differential out from end cover

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

B - Spindle from counter support Kukko 22/2

Scheme 32

Driving needle bearing for Torsen differential flush into end cover

1. Fit press plate VW 412 onto bearing with shoulder facing up.

Bearing plate, servicing

Special tools, testers and auxiliary items required

1. Internal puller 18.5-23.5 mm (e.g. Kukko 21/3)
2. Counter support (e.g. Kukko 22/1)
3. Press tool VW 408a
4. Guide pin 10-15
5. Thrust pad 30-504
6. Depth gauge

Note. The following list refers to (Scheme 103).

1. Bearing plate If replacing, re-determine shim "S4"
2. Outer race for taper roller bearing for drive pinion Driving out. See «DRIVING OUT OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). Pressing in. See «PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-in-outer-race-for-small). If replacing, re-determine shim "S4"
3. Shim "S4" Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview). Re-determining. See «SHIM "S4," RE-DETERMINING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__shim-s4-re-determining).
4. Cylinder roller bearing for input shaft Pressing out. See «PRESSING CYLINDER ROLLER BEARING FOR INPUT SHAFT OUT OF BEARING PLATE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). Pressing in. See «PRESSING CYLINDER ROLLER BEARING FOR INPUT SHAFT INTO BEARING PLATE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-cylinder-roller-bearing-for-input). Measuring insertion depth. See «MEASURING INSERTION DEPTH OF CYLINDER ROLLER BEARING FOR INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__measuring-insertion-depth-of-cylinder-roller).
5. Ball sleeve For selector rods Removing and installing. See «REMOVING AND INSTALLING BALL SLEEVES FOR SELECTOR RODS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-and-installing-ball-sleeves-for). Replace
6. Bolt, 35 Nm For relay lever
7. Dowel pin (7 x 28) Press in flush
8. Sliding gear for reverse gear
9. Synchro-ring for reverse gear With locking pins Checking for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__checking-synchro-ring-for-wear). Installation position: flat on circumference of synchro-ring faces towards input shaft. (Scheme 46)
10. Spring Installation position: hook single angled end into recess on synchroring. Turn double angled end anti-clockwise and insert into opening on bearing plate.
11. Shaft for reverse sliding gear
12. Retaining plate Installation position: the chamfers of the holes for the locking pins of the synchro-ring towards bearing plate. (Scheme 47)
13. Spring clasp
14. Bolt, 25 Nm Self-locking Replace
15. Relay lever for reverse gear
16. Follower for reverse gear Pulling out ball sleeve. See «PULLING BALL SLEEVE OUT OF FOLLOWER FOR REVERSE GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-ball-sleeve-out-of-follower). Driving in ball sleeve. See «DRIVING BALL SLEEVE FLUSH INTO FOLLOWER FOR REVERSE GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
17. Selector rod for 5th and 6th gear Replace only complete with follower.

Removing and installing ball sleeves for selector rods

1. Insertion depth a = 2.5 mm

Checking synchro-ring for wear

1. Press synchro-ring onto cone of the gear.
2. Measure gap "a" with a feeler gauge: Dimension, new: 0.75-2.3 mm Wear limit: 0.2 mm

Pulling ball sleeve out of follower for reverse gear

A - Counter support, e.g. Kukko 22/1

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

Scheme 33

Scheme 34

Scheme 35

Pressing cylinder roller bearing for input shaft into bearing plate

Insertion depth depends on serial number of transmission.

1. Measuring insertion depth. See «MEASURING INSERTION DEPTH OF CYLINDER ROLLER BEARING FOR INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__measuring-insertion-depth-of-cylinder-roller) .

Measuring insertion depth of cylinder roller bearing for input shaft

a = 7 mm

Scheme 36

Shim "S4," re-determining

Special tools, testers and auxiliary items required

1. End measuring plate VW 385/32
2. Clamping sleeve 3116
3. Hex bolt 3116/1
4. Depth gauge, accurate to 5/100 mm
5. Caliper gauge, accurate to 5/100 mm
6. Torque wrench

This adjustment is necessary when replacing following components

1. Bearing plate. See «DETERMINING SHIM WHEN REPLACING BEARING PLATE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
2. Hollow shaft. See «DETERMINING SHIM WHEN REPLACING HOLLOW SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-shim-when-replacing-hollow-shaft) .

This adjustment re-creates the preload of the taper rollers for the drive pinion and hollow shaft.

Note. The following list refers to (Scheme 111).

1. Shim "S4"
2. Bearing plate
3. Transmission housing
4. Hollow shaft
5. Drive pinion/hollow shaft taper roller bearing
6. Drive pinion a - Bearing plate housing depth b - Dimension from drive pinion head to contact shoulder of taper roller bearing on hollow shaft Taper roller bearings (drive pinion/hollow shaft) preloaded to 10 Nm. See «DETERMINING SHIM WHEN REPLACING HOLLOW SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-shim-when-replacing-hollow-shaft) . S4 - Thickness of shim "S4" NOTE: When replacing the drive pinion (final drive set), observe adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview) .

Scheme 37

Scheme 38

1. Use a depth gauge which is accurate to within at least 5/100 mm.
2. Measure difference of depth "a" on old and new bearing plates. Example
3. If the new bearing plate is deeper, install a thicker "S4" shim.
4. If the old bearing plate is deeper, install a thinner "S4" shim.

Example

Scheme 39

Available shims, table. See AVAILABLE SHIMS FOR "S4" .

Determining shim when replacing hollow shaft

1. Use a caliper gauge which is accurate to within at least 5/100 mm.
2. Tighten tensioning sleeve to exactly 10 Nm. A - Vice clamps
3. Fit end measuring plate VW 385/32 onto drive pinion head and measure dimension "d". (Scheme 116) Upper measuring point is the contact shoulder for inner race of small taper roller bearing. Example: 248.50 mm
4. Install new hollow shaft and measure dimension "d" again. Example: 248.70 mm
5. Determine difference
6. Install a correspondingly thinner shim "S4" if dimension "d" of new hollow shaft is greater.
7. Install a correspondingly thicker shim "S4" if dimension "d" of new hollow shaft is less.
8. Determine shim(s) from «S4 SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

Available shims for "S4"

S4 SHIM THICKNESS AVAILABILITY

Transmission housing, servicing

Special tools, testers and auxiliary items required

1. Multi-purpose tool 771/1 with attachment 771/15
2. Mandrel 2062
3. Press tool VW 408 A
4. Tube VW 423
5. Thrust pad VW 454
6. Extractor lever VW 681
7. Guide pin 10-15
8. Drift sleeve 30-100
9. Mandrel 30-505
10. Installing tool 40-503
11. Internal puller 14.5-18.5 mm e.g. Kukko 21/2
12. Internal puller 30-37 mm e.g. Kukko 21/5
13. Depth gauge
14. Assembly sleeve, Part No. 01E 311 120

Note. Refer to general repair instructions. See REPAIR INSTRUCTIONS . Adjustments are required when replacing components marked with a "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to (Scheme 118).

1. Seal For drive flange Pulling out. See «PULLING OUT SEAL FOR DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-seal-for-drive-flange). Driving in. See «DRIVING IN SEAL FOR DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal-for-drive-flange). Fill space between sealing lips with sealing grease G52 128 A1. Replacing with transmission installed. See «DRIVE FLANGE SEAL, REPLACING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
2. Final drive cover 1)
3. O-ring For cover for final drive Replace
4. Shim "S1" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview).
5. Outer race for large taper roller bearing 1) For differential Driving out and driving in. See «DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
6. Outer race for small taper roller bearing 1) For differential Driving out and driving in. See «DRIVING OUTER RACE FOR SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
7. Shim "S2" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview).
8. Seal For input shaft Levering out. See «LEVERING OUT SEAL FOR INPUT SHAFT WHEN TRANSMISSION IS DISMANTLED»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__levering-out-seal-for-input-shaft). Driving in. See «DRIVING IN SEAL FOR INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal-for-input-shaft). Always replace when removing input shaft Replacing when transmission is not disassembled. See «REMOVING SEAL FOR INPUT SHAFT WHEN TRANSMISSION IS NOT DISMANTLED»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-seal-for-input-shaft-when) and «DRIVING IN SEAL FOR INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal-for-input-shaft).
9. Oil drain plug, 40 Nm
10. Ball sleeve For selector shaft Replace Pulling out. See «PULLING OUT BALL SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-ball-sleeve). Driving in. See «DRIVING IN BALL SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-ball-sleeve).
11. Ball sleeves For selector shafts Replace Pulling out, as -10-. See «PULLING OUT BALL SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-ball-sleeve). Driving in, as -10-. See «DRIVING IN BALL SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-ball-sleeve).
12. Circlip Installation position: eyes facing up
13. Switch for reversing lights, 20 Nm
14. O-ring For cover for selector shaft Replace
15. Cover for selector shaft Removing. (Scheme 25) Installing. (Scheme 72)
16. Ball stud, 20 Nm For connecting rod
17. Outer race for large taper roller bearing 1) For drive pinion Pulling out. See «PULLING OUT OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-outer-race-for-large). Pressing in. See «HEATING GEARBOX HOUSING TO INSERT THE OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__heating-gearbox-housing-to-insert-the) and «INSERTING OUTER RACE FOR LARGE TAPER ROLLER BEARING IN GEARBOX HOUSING AND PRESSING HOME»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-outer-race-for-large-taper).
18. Circlip Removing. See «REMOVING CIRCLIP»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-circlip).
19. Shim "S3" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview).
20. Needle bearing For input shaft Pulling out. See «PULLING NEEDLE BEARING OUT OF TRANSMISSION HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-needle-bearing-out-of-transmission). Driving in. See «DRIVING NEEDLE BEARING INTO TRANSMISSION HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-needle-bearing-into-transmission-housing). Measuring insertion depth. See «INSERTION DEPTH OF NEEDLE BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__insertion-depth-of-needle-bearing).
21. Locking bolt For selector shaft Removing. (Scheme 25) Installing. (Scheme 72) Tightening torques: For aluminium bolt = 50 Nm, and for steel bolt = 70 Nm
22. Stud, 40 Nm For pushrod No longer installed from m.y. 1999 and up
23. Breather Clip cap on For transmission with sleeve insertion depth of sleeve. See «INSERTION DEPTH OF BREATHER SLEEVE FOR TRANSMISSIONS WITHOUT BREATHER HOSE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__insertion-depth-of-breather-sleeve-for). For transmission with additional breather hose. See «BREATHER FOR TRANSMISSION WITH BREATHER HOSE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__breather-for-transmission-with-breather-hose).
24. Seal for selector shaft Can be replaced when transmission is removed but not dismantled Replace Pulling out. See «PULLING OUT SEAL FOR SELECTOR SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-seal-for-selector-shaft). Driving in. See «DRIVING IN SEAL FOR SELECTOR SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal-for-selector-shaft). Always use assembly sleeve for installing. See «INSTALLING SEAL AND SELECTOR SHAFT WITH ASSEMBLY SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-seal-and-selector-shaft-with).
25. Transmission housing 1) With oil baffle plate for transmission with transmission oil cooler Installation position of oil baffle plate. See «INSTALLATION POSITION OF OIL BAFFLE PLATE ONLY FOR TRANSMISSION WITH TRANSMISSION OIL COOLER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installation-position-of-oil-baffle-plate).
26. Magnet Clean When replacing transmission housing drive in with e.g. press tool VW 408 A
27. Sender for speedometer -G22- Replacing. See «SPEEDOMETER SENDER -G22- AND DRIVE WHEEL FOR SPEEDOMETER SENDER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__speedometer-sender-g22-and-drive-wheel).
28. O-ring Replace
29. Oil filler plug, 40 Nm

Pulling out seal for drive flange

Note. Illustrated, removing oil seal on right-hand side. Procedure for removing oil seal on left and right-hand sides is identical.

Scheme 40

Driving in seal for drive flange

1. Fill space between sealing lip and dust lip with sealing grease G52 128 A1.

1. Pressing-in depth (factory): 5.5 mm
2. Pressing-in depth when re-installing a used drive flange (repairs): 6.5 mm

Scheme 41

Note. Illustrated, installing oil seal on right-hand side. Procedure for installing oil seal on left and right-hand sides is identical.

Levering out seal for input shaft when transmission is dismantled

1. Lever out seal carefully with VW 681.

Removing seal for input shaft when transmission is not dismantled

1. Lever out seal carefully with a screwdriver.

Note. Do not damage bearing surface on input shaft for shaft seal.

Driving in seal for input shaft

1. Fill space between sealing lip and dust lip of new seal for input shaft with sealing grease G52 128 A1.
2. Fit a thin protective hose tightly over splines of input shaft.
3. Drive in seal for input shaft. Pressing-in depth (factory): 3.5 mm Pressing-in depth when re-installing a used input shaft (repairs): 4.5 mm
4. Remove protective hose.

Pulling out ball sleeve

1. Remove circlip. A - Internal puller 14.5-18.5 mm, e.g. Kukko 21/2

Driving in ball sleeve

1. Drive in onto stop.

Pulling out seal for selector shaft

Note. With transmission removed but not dismantled, carefully lever out seal without damaging the shaft with a screwdriver.

Scheme 42

Driving in seal for selector shaft

1. Selector shaft installed or removed

1. Fill space between sealing lip and dust lip with sealing grease G52 128 A1.
2. Pull assembly sleeve onto selector shaft. See «INSTALLING SEAL AND SELECTOR SHAFT WITH ASSEMBLY SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-seal-and-selector-shaft-with) .
3. Drive seal into housing onto stop.

Installing seal and selector shaft with assembly sleeve

1. To avoid damaging the seal-C-always use assembly sleeve -A-, Part No. 01E 311 120, to install seal or selector shaft.

Insertion depth of breather sleeve for transmissions without breather hose

1. Dimension a = 21 mm

Breather for transmission with breather hose

1. Transmission
2. Sleeve: drive in onto stop
3. Pipe: drive in onto stop
4. Clamp
5. Hose
6. Breather pipe
7. Retaining clip

Pulling needle bearing out of transmission housing

A - Internal puller 30-37 mm, e.g. Kukko 21/5

Scheme 43

Driving needle bearing into transmission housing

1. Installation position: inscription on bearing faces tool
2. Insertion depth. See «INSERTION DEPTH OF NEEDLE BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__insertion-depth-of-needle-bearing) .

Insertion depth of needle bearing

Dimension a = 105 mm

Scheme 44

Removing circlip

1. Lift circlip out of the groove by turning one end of the circlip with a screwdriver -A-.
2. Secure this end with a screwdriver -B-.
3. Lever circlip out further by repositioning screwdriver -A-.

Installation position of oil baffle plate only for transmission with transmission oil cooler

1. Breather
2. Oil baffle plate
3. Selector shaft

Selector shaft (complete), disassembling and assembling

Note. The following list refers to (Scheme 136).

1. Selector cylinder
2. Roll pin Drive out and drive in flush. See «DRIVING OUT AND DRIVING IN ROLL PIN FLUSH»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-out-and-driving-in-roll) .
3. Selector shaft Driving out. See «DRIVING OUT SELECTOR SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-out-selector-shaft) . Driving in. See «DRIVING IN SELECTOR SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-selector-shaft) . Installation position: flat (arrow) and selector finger -4- face in same direction
4. Selector finger Observe installation position to -3
5. Cam for reversing light switch

Driving out and driving in roll pin flush

A - Drift

B - Vice clamps

Scheme 45

Driving out selector shaft

A - Drift

B - Vice clamps

Scheme 46

1. For read measuring value block, go to .

Driving in selector shaft

A - Wooden block

Note. Bring holes into alignment. Flat on selector shaft and selector finger point in same direction.

Scheme 47

Input shaft, disassembling and assembling

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Press tool VW 412
3. Tube VW 519
4. Feeler gauge

Note. When installing new gears see Technical data. See CODE LETTERS, ALLOCATION, RATIOS, AND CAPACITIES .

Note. The following list refers to (Scheme 140).

1. Gearbox housing Servicing. See «TRANSMISSION HOUSING, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__transmission-housing-servicing).
2. Circlip
3. Thrust washer
4. Needle bearing for 4th gear Mark before removing Do not interchange with needle bearing for 3rd gear Oil with gear oil before installing
5. 4th speed sliding gear Before installing, insert spring. See «INSERTING SPRING IN SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-spring-in-sliding-gear). After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
6. Synchro-ring for 4th gear Check for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
7. Locking collar Paired with synchro-hub Mark before removing. (Scheme 34)
8. Circlip Re-determine thickness when replacing synchro-hub. See «RE-DETERMINING THICKNESS OF CIRCLIP»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__re-determining-thickness-of-circlip). Installation position: ends align with groove of synchro-hub
9. Synchro-hub for 3rd and 4th gear Pressing off. See «PRESSING OFF SYNCHRO-HUB FOR 3RD AND 4TH GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). Installation position. See «SYNCHRO-HUB INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__synchro-hub-installation-position). Pressing on. See «PRESSING ON SYNCHRO-HUB FOR 3RD AND 4TH GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-on-synchro-hub-for-3rd-and).
10. Synchro-ring for 3rd gear Coated with molybdenum Check for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
11. 3rd speed sliding gear Before installing, insert spring. See «INSERTING SPRING IN SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-spring-in-sliding-gear). After pressing on -item 9-, check axial clearance with a feeler gauge (0.15-0.35 mm)
12. Needle bearing for 3rd gear Mark before removing Do not interchange with needle bearing for 4th gear Oil with gear oil before installing
13. Input shaft
14. Spring pin Drive in when replacing input shaft. See «DRIVING SPRING PIN INTO INPUT SHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-spring-pin-into-input-shaft).
15. Bearing plate Servicing. See «BEARING PLATE, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearing-plate-servicing).
16. Inner race for cylinder roller bearing Take off and fit by hand
17. Circlip
18. Thrust washer for needle bearing for 6th gear Installation position: shoulder towards circlip, smooth contact surface towards needle bearing. (Scheme 54)
19. Needle bearing for 6th gear Oil with gear oil before installing
20. 6th speed sliding gear Before installing, insert spring. See «INSERTING SPRING IN SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-spring-in-sliding-gear). After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
21. Synchro-ring for 6th gear Check for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
22. Synchro-hub for 5th and 6th gear Pulling off. (Scheme 35) Driving on. (Scheme 56) Installation position: projecting hub towards 5th speed sliding gear
23. Locking collar Paired with synchro-hub Mark before removing. (Scheme 34)
24. Synchro-ring for 5th gear Checking for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
25. 5th speed sliding gear Before installing, insert spring. See «INSERTING SPRING IN SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-spring-in-sliding-gear). After installing, check axial clearance. (Scheme 65)
26. Inner race for 5th speed sliding gear Pulling off. (Scheme 35) Driving on. (Scheme 64)
27. Needle bearing for 5th gear Oil with gear oil before installing
28. 1st inner race for tapered roller bearing for input shaft Pulling off. (Scheme 29) Driving on. (Scheme 65)
29. End cover Servicing. See «END COVER, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__end-cover-servicing).
30. 2nd inner race for tapered roller bearing for input shaft Pulling off. (Scheme 29) Driving on. (Scheme 67)
31. Multi-point socket head bolt, 150 Nm Loosening and tightening. (Scheme 27)

Inserting spring in sliding gear

1. Insert spring (arrow) in sliding gear, hook angled end into hole.

1. Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
2. Add together results and divide by three. The figure calculated must not be less than 0.5 mm

Re-determining thickness of circlip

1. Press synchro-hub onto stop.

Note. Note installation position when pressing on. See Synchro-hub installation position .

1. Determine the thickest circlip that can still just be fitted.

Note. The opening of the circlip must align with the groove in the synchro-hub.

1. Determine circlip from «INPUT SHAFT CIRCLIP THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

Circlips available

INPUT SHAFT CIRCLIP THICKNESS AVAILABILITY

1. Fit circlip.

Scheme 48

Synchro-hub installation position

1. Oil groove in synchro hub (arrow -1-) must align with oil drilling -arrow 2- in input shaft

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

1. Heat synchro-hub to approx. 100° C, fit and press home.
2. Fit circlip.

Driving spring pin into input shaft

1. Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B- in until it touches drift.

Drive pinion and hollow shaft, disassembling and assembling

Special tools, testers and auxiliary items required

1. Multi-purpose tool 771/1 with attachment 771/15
2. Installing sleeve 2003/3
3. Punch 3013
4. Thrust pad 3062
5. Thrust piece 3118
6. Drift 3138
7. Drift VW 295
8. Thrust plate VW 401
9. Thrust plate VW 402
10. Press tool VW 407
11. Press tool VW 411
12. Press tool VW 412
13. Tube VW 415a
14. Support rails VW 457
15. Separating device 22-115 mm (e.g. Kukko 17/2)
16. Internal puller 12-14.5 mm (e.g. Kukko 22/1)
17. Hot air blower V.A.G 1416

Note. When installing new gears or final drive set. See CODE LETTERS, ALLOCATION, RATIOS, AND CAPACITIES . Adjustments are required when replacing components marked with a " 1) ." See ADJUSTMENT OVERVIEW .

Note. The following list refers to (Scheme 148).

1. Gearbox housing Servicing. See «TRANSMISSION HOUSING, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__transmission-housing-servicing).
2. Shim "S3" Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview).
3. Outer race for large taper roller bearing 1) Pulling out. See «PULLING OUT OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-outer-race-for-large). Pressing in. See «HEATING GEARBOX HOUSING TO INSERT THE OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__heating-gearbox-housing-to-insert-the) and «INSERTING OUTER RACE FOR LARGE TAPER ROLLER BEARING IN GEARBOX HOUSING AND PRESSING HOME»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-outer-race-for-large-taper).
4. Drive pinion 1) Paired with crown wheel (final drive set)
5. Needle bearing for flange shaft/drive pinion Pulling out. See «PULLING OUT NEEDLE BEARING FOR FLANGE SHAFT/DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-needle-bearing-for-flange). Driving in. See «DRIVING NEEDLE BEARING FOR FLANGE SHAFT/ DRIVE PINION IN FLUSH»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
6. Inner race for large taper roller bearing 1) Pressing off. See «PRESSING OFF INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-off-inner-race-for-large). Pressing on. See «PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-on-inner-race-for-large). Low-friction bearing; do not oil when measuring friction torque
7. Circlip Re-determining. See «DETERMINING CIRCLIP FOR LARGE TAPER ROLLER BEARING FOR DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-circlip-for-large-taper-roller).
8. Flange ring Installation position. (Scheme 42)
9. Tapered rollers Qty. 23 Installation position. (Scheme 42)
10. Support ring Installation position. (Scheme 42)
11. Corrugated spring
12. Needle bearing for drive pinion/hollow shaft Oil before installing
13. Hollow shaft with 3rd and 4th speed gears 1)
14. Needle bearing for 2nd speed sliding gear Split Oil with gear oil before installing
15. 2nd speed sliding gear Pressing off. See «PRESSING OFF 2ND SPEED SLIDING GEAR WITH SYNCHRO-HUB FOR 1ST AND 2ND GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-off-2nd-speed-sliding-gear). Before installing, fit spring and slide needle bearing onto hollow shaft After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
16. Synchro-ring for 2nd gear Coated with Molybdenum Checking for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
17. Synchro-hub for 1st and 2nd gear Pressing off. See «PRESSING OFF 2ND SPEED SLIDING GEAR WITH SYNCHRO-HUB FOR 1ST AND 2ND GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-off-2nd-speed-sliding-gear). Pressing on. See «FITTING 2ND SPEED SLIDING GEAR, PRESSING ON SYNCHRO-HUB FOR 1ST AND 2ND GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__fitting-2nd-speed-sliding-gear-pressing). Installation position: flush hub towards 2nd speed sliding gear
18. Circlip Removing and installing. See «REMOVING AND INSTALLING CIRCLIP FOR SYNCHRO-HUB AND SHIM FOR 1ST SPEED SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-and-installing-circlip-for-synchro-hub). Re-determining. See «DETERMINING CIRCLIP FOR LARGE TAPER ROLLER BEARING FOR DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-circlip-for-large-taper-roller).
19. Washer Removing and installing. See «REMOVING AND INSTALLING CIRCLIP FOR SYNCHRO-HUB AND SHIM FOR 1ST SPEED SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-and-installing-circlip-for-synchro-hub).
20. Locking collar for 1st and 2nd gear Installation position: splines for reverse gear towards synchro-ring for 2nd gear
21. Synchro-ring for 1st gear Checking for wear. See «CHECKING SYNCHRO-RING FOR WEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
22. Needle bearing for 1st speed sliding gear Oil with gear oil before installing
23. 1st speed sliding gear Before installing, insert spring. See «INSERTING SPRING IN SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__inserting-spring-in-sliding-gear). After pressing on -item 24-, check axial clearance
24. Inner race for small taper roller bearing 1 ) Pressing off. See «PRESSING OFF INNER RACE OF SMALL TAPER ROLLER BEARING FOR DRIVE PINION TOGETHER WITH 1ST SPEED SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-off-inner-race-of-small). Pressing on. See «PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING FOR DRIVE PINION TOGETHER WITH 1ST SPEED SLIDING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-on-inner-race-for-small). Low friction bearing; do not oil when measuring friction torque
25. Outer race for small taper roller bearing 1) Driving out. See «DRIVING OUT OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). Pressing in. See «PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-in-outer-race-for-small).
26. Shim "S4" Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview).
27. Bearing plate 1) Servicing. See «BEARING PLATE, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__bearing-plate-servicing).
28. 6th gear wheel Pressing off. (Scheme 43) Pressing on. (Scheme 44) Installation position: shoulder towards inner race for small taper roller bearing
29. Spacer sleeve
30. Shim Re-determining. See «5TH SPEED GEAR SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
31. 5th gear wheel Pulling off. (Scheme 31) Driving on. (Scheme 62)
32. Circlip for 5th gear wheel Re-determining. (Scheme 63)
33. End cover Servicing. See «END COVER, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__end-cover-servicing).

Pulling out outer race for large taper roller bearing

1. Stepped side of thrust pad 3062 rests against the outer race

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

1. Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 ° C, with a hot air blower.

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

1. Insert outer race only after heating gearbox housing and press home for 1-2 minutes under a repair press until a heat exchange has taken place.

Pulling out needle bearing for flange shaft/drive pinion

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

Scheme 49

Scheme 50

Pressing off inner race for large taper roller bearing

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

1. Bearing is destroyed when pressing off

Pressing on inner race for large taper roller bearing

1. Heat inner race to approx. 100 °C and fit.
2. Press home ensuring there is no axial play.

Determining circlip for large taper roller bearing for drive pinion

1. Determine the thickest circlip that can still just befitted.
2. Determine circlip from «DRIVE PINION LARGE TAPER ROLLER BEARING CIRCLIP THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

Scheme 51

The following circlips are available

DRIVE PINION LARGE TAPER ROLLER BEARING CIRCLIP THICKNESS AVAILABILITY

1. Fit circlip.

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

Note. Do not press off together with 1st and 2nd gear synchro-hub and 2nd speed sliding gear.

Scheme 52

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

1. Install circlip, shim for 1st speed sliding gear, synchro-ring for 1st speed, and 1st speed sliding gear with spring and needle bearing.
2. Heat inner race to approx. 100° C and fit.
3. Press home ensuring there is no axial play.

Note. With shoulder of thrust piece 3118 facing downwards, press only onto bearing inner race. Position stepped shoulder of tube VW 415A facing up towards press tool VW 412. After pressing on, check axial clearance of 1st speed sliding gear.

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

1. Removing, take off shim -A- then circlip -B-.
2. Installing, fit circlip -B- then shim -A-.

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

1. Take off locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
2. Remove shim and circlip for synchro-hub.
3. Press off 2nd speed sliding gear together with synchro-hub for 1st and 2nd gear.

Scheme 53

Note. Do not press off together with 1st speed sliding gear and inner race for small taper roller bearing.

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

1. Install needle bearing (split), sliding gear with spring and synchro-ring for 2nd gear.
2. Oil needle bearing.
3. Heat synchro-hub to approx. 100° C and fit.
4. Press home ensuring there is no axial play.

Note. Position tube VW 415 a with shoulder towards synchro-hub. Position thrust pad 3118 with stepped shoulder towards press tool VW 412.

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

1. Determine the thickest circlip that can still just be fitted.
2. Determine circlip from «CIRCLIP FOR SYNCHRO-HUB FOR 1ST AND 2ND GEAR THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

Scheme 54

The following circlips are available

CIRCLIP FOR SYNCHRO-HUB FOR 1ST AND 2ND GEAR THICKNESS AVAILABILITY

1. Fit circlip in direction of arrow onto synchro-hub.

Scheme 55

Pressing in outer race for small taper roller bearing

1. Insert shim "S4" into bearing flange behind bearing seat.
2. Position stepped shoulder of thrust pad 3062 towards press tool VW 407.
3. Press outer race for small taper roller bearing onto stop.

1. Arbor VW 195
2. Extractor lever VW 681
3. Drip tray V.A.G 1306

1. Transmission installed

Note. Illustrated, removing and installing oil seal on left-hand side. Procedure for removing oil seal on left and right-hand sides is identical.

1. Remove heat shield.
2. Disconnect drive axle.
3. Place a drip tray underneath.
4. Remove drive flange, secure with a drift to prevent it turning.
5. Pull seal out with lever VW 681.

Installing

1. Fill space between sealing and dust lips with sealing grease G52 128 A1.
2. Lightly oil outer circumference of seal.
3. 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
4. Install drive flange and drive axle.

Tightening torques

TIGHTENING TORQUES: DRIVE FLANGE

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

1. Transmission installed

Removing and installing speedometer sender -G22

1. Pull connector off sender -B-.
2. Press sender retainer down, turn and pull out sender.
3. Replace O-ring -A-.

Scheme 56

1. Detach drive axle from left drive flange -B-.
2. Unscrew bolt -A-. Secure drive flange with a drift to prevent it turning. (Scheme 171)
3. Remove drive flange and seal -C-.
4. Using a screwdriver, lever out drive wheel for speedometer sender -D- on alternate sides at the follower lugs (arrows).

1. Install drive wheel for speedometer sender so that the follower lugs (arrows) face toward the seal. 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.
2. Follower lugs engage in differential housing grooves.
3. Replace seal for drive flange and install drive flange. See «DRIVE FLANGE SEAL, REPLACING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Top up oil in transmission and check oil level. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level) .

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

Special tools, testers and auxiliary items required

1. Drip tray V.A.G 1306
2. Adapter VW 295a
3. Thrust plate VW 401
4. Thrust plate VW 402
5. Press tool VW 407
6. Tube VW 415a
7. Tube VW 416b
8. Press tool VW 433
9. Thrust pad VW 454
10. Extractor lever VW 681
11. Multi-purpose tool 771/1 with attachment 771/15 and stud M8/M10
12. Punch 2005
13. Shim, Part No. 016 311 391 B

Note. The following list refers to (Scheme 173).

1. Transmission
2. Grooved ball bearing
3. Bearing housing on balance weight
4. Seal Driving in. (Scheme 180)
5. Drive flange
6. Bolt, 25 Nm Qty. 6
7. O-ring Replace
8. Circlip
9. Spring plate Mark installation position when removing: larger diameter (concave side) towards shims - 10
10. Shims
11. Spring
12. Oil drain plug, 40 Nm

1. Transmission installed

1. Disconnect driveshaft at the front, lift clear and tie-up on selector linkage. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
2. Place a drip tray underneath.
3. Unscrew rear oil drain plug (on end cover) and drain transmission oil.
4. Unscrew securing bolts for bearing housing. NOTE: Generally, the bearing housing is pressed out via the spiral spring when loosening bolts from cover. If the bearing housing is not pressed off
5. Pull drive flange together with bearing housing balance weight off end cover. A-M8/M10 stud
6. Take off bearing housing.
7. Take circlip off drive flange.
8. Press out drive flange.
9. Pull out seal for drive flange.
10. Thoroughly clean seal seat.
11. Press out grooved ball bearing.

1. Press grooved ball bearing in bearing housing.
2. Lightly oil outer circumference of seal -B-. (Scheme 179)
3. Fill space between sealing lips and dust lips with sealing grease G52 128 A1.
4. Fit seal with shim -A-, Part No. 016 311 391 B (1.7 mm thick) onto punch 2005. (Scheme 179) Installation position: open side of seal towards transmission.
5. Drive in seal for drive flange.
6. Remove shim after driving in.
7. Press in drive flange.
8. Fit circlip onto drive flange.
9. Lightly oil O-ring and fit into bearing housing groove.
10. Insert spring plate and shims into bearing housing. Installation position:. (Scheme 173)
11. Slide coil spring onto drive flange.
12. Tighten securing bolts for bearing housing in diagonal sequence and in stages to 25 Nm.
13. Bolt on driveshaft. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
14. Top up oil in transmission and check oil level. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level).

Differential, removing and installing

Note. Removing and installing is also possible with transmission installed in vehicle.

Note. The following list refers to (Scheme 182).

1. Bolt, 10 Nm +1/4 turn (90 °) further
2. Drive flange When removing, secure with a drift to prevent it turning
3. Bolt, 25 Nm Qty. 10
4. Cover for final drive Removing and installing drive wheel for speedometer sender -G22-. See «SPEEDOMETER SENDER -G22- AND DRIVE WHEEL FOR SPEEDOMETER SENDER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__speedometer-sender-g22-and-drive-wheel) . If replaced: adjust ring gear. See «RING GEAR, ADJUSTING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__ring-gear-adjusting) .
5. Oil filler plug, 40 Nm Checking oil level in transmission. See «CHECKING FLUID LEVEL»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__checking-fluid-level) .
6. Differential Disassembling and assembling. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__differential-disassembling-and-assembling) . If replaced: adjust ring gear. See «RING GEAR, ADJUSTING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__ring-gear-adjusting) .
7. Transmission housing Servicing. See «TRANSMISSION HOUSING, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__transmission-housing-servicing) .

Differential, disassembling and assembling

Special tools, testers and auxiliary items required

1. Drift VW 295
2. Thrust plate VW 401
3. Thrust plate VW 402
4. Press tool VW 412
5. Installing tool VW 459/2
6. Thrust plate 30-205
7. Mandrel 30-505
8. Press tool 40-21
9. Thrust plate 40-105
10. Thrust pad 3062
11. Drift 3138
12. Taper roller bearing puller V.A.G 1582
13. Grip V.A.G 1582/3
14. Grip V.A.G 1582/6

Note. Removing and installing differential. See DIFFERENTIAL, REMOVING AND INSTALLING . Adjustments are required when replacing components marked with a " 1) ". See ADJUSTMENT OVERVIEW .

Note. The following list refers to (Scheme 183).

1. Transmission housing 1)
2. Shim "S2" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview) .
3. Outer race for small taper roller bearing 1) Driving out. See «DRIVING OUTER RACE FOR SMALL TAPER ROLLER BEARING OUT OF TRANSMISSION HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Driving in. See «DRIVING OUTER RACE FOR SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Inner race for small taper roller bearing 1) Pulling out. See «PULLING INNER RACE FOR SMALL TAPER ROLLER BEARING OUT OF HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-inner-race-for-small-taper) . Pressing in. See «PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-on-inner-race-for-small) . Low friction bearing; do not oil when measuring frictional torque
5. Ring gear 1) Paired with drive pinion (final drive set) Removing. See «DRIVING RING GEAR OFF HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Installing. See «INSTALLING RING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-ring-gear) .
6. Differential housing 1)
7. Ring gear bolt, 60 Nm + 45 ° further Always replace Use only genuine bolts
8. Inner race for large taper roller bearing 1) Pulling off. See «PULLING INNER RACE FOR LARGE TAPER ROLLER BEARING OFF HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-inner-race-for-large-taper) . Pressing on. See «PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Low friction bearing; do not oil when measuring frictional torque.
9. Drive wheel For speedometer sender Removing and installing. See «SPEEDOMETER SENDER -G22- AND DRIVE WHEEL FOR SPEEDOMETER SENDER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__speedometer-sender-g22-and-drive-wheel) . 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: shoulder (arrow) towards differential
10. Outer race for large taper roller bearing 1) Driving out. See «DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-outer-race-for-large-taper) . Driving in. See «DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
11. Shim "S1" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjustment-overview) .
12. Cover for final drive 1) With O-ring Replace O-ring Oil O-ring before installing
13. Shims Re-determining thickness. See «ADJUSTING PLANET WHEELS AND SUN WHEELS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
14. Sun wheels Adjusting. See «ADJUSTING PLANET WHEELS AND SUN WHEELS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
15. Threaded piece
16. Thrust washer Check for cracks and chipping
17. Planet wheels Installing. See «INSTALLING PLANET WHEELS AND SUN WHEELS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
18. Shaft for planet wheels Drive out with drift after removing spring pin Before driving in, align thrust washers
19. Spring pin Drive in flush

Pulling inner race for small taper roller bearing out of housing

1. Fit thrust plate 40-105 before fitting puller.

Pulling inner race for large taper roller bearing off housing

1. Fit thrust plate 40-105 before fitting puller.

Pressing on inner race for small taper roller bearing

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

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

Scheme 57

Installing ring gear

1. Use 2 centering pins -A- (local manufacture) as a guide. CAUTION: Wear protective gloves.
2. Heat ring gear to approx. 100 °C and install.
3. Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to specified torque.

Scheme 58

1. Carefully lever out drive wheel for speedometer sender with a screwdriver.
2. Insert thrust washers for planet wheels with a small amount of grease.
3. Insert sun wheels with selected shims. See «ADJUSTING PLANET WHEELS AND SUN WHEELS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Insert planet wheels spaced 180° apart and rotate into position (arrow).
5. Insert threaded pieces. Installation position: stepped shoulder towards sun wheels
6. Locate thrust washers and planet wheels so that they align with the holes.
7. Drive planet pinion shaft into final position and secure.

Scheme 59

Scheme 60

1. Insert sun wheels with thinnest shims (0.5 mm).
2. Insert planet wheels with thrust washers and press in shaft. NOTE: Do not now interchange bevel gears and thrust washers!
3. Press planet wheels outwards and check play of sun wheels by hand (arrows).
4. Adjust play by inserting an appropriate shim. See «SHIM THICKNESS CHART»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Specification: max. 0.10 mm NOTE: The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears (arrow).
5. Determine shim from «DIFFERENTIAL PLANET WHEEL SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table. The following shims are available: DIFFERENTIAL PLANET WHEEL SHIM THICKNESS AVAILABILITY Shim thickness (mm) 0.50 0.70 0.90 0.60 0.80 1.00

Scheme 61

Scheme 62

Driving outer race for large taper roller bearing out of cover

1. Use suitable base, for example VW 470, with recess towards cover.

Scheme 63

Drive pinion and ring gear, adjusting

Note. 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. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production. The deviation (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. Observe the general repair instructions for taper roller bearings and shims. The frictional torque measurement is only used as a final check to make sure that the adjustment is correct.

Gear sets, adjusting and marking

1. 1 - Identification "0937" signifies Oerlikon gear set with a ratio of 37:9.
2. 2 - Pairing number (312) of final drive set.
3. 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
4. Ro - Length of master gauge used on test machine Ro = 59.65 mm
5. R - Actual distance between ring gear axis and face of drive pinion at point with quietest running for this gear set R = Ro + r
6. Vo - Hypoid offset

Final drive set readjusting, recommended sequence

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

1. Determine total shim thickness "S total " for "S1" +"S2" (sets preload for taper roller bearings for differential). See «DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S1" + "S2"»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-total-shim-thickness-stotal-for) .
2. Determine total shim thickness "S total " for "S3" + "S4" (sets preload for taper roller bearings for drive pinion). See «DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S3" + "S4"»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-total-shim-thickness-stotal-for) .
3. Distribute total shim thickness "S total " 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. See «DETERMINING THICKNESS OF SHIM "S3"»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-thickness-of-shim-s3) .
4. Distribute total shim thickness "S total " for "S1" + "S2" so that the specified backlash between ring gear and drive pinion is maintained. See «DETERMINING THICKNESS OF SHIM "S2"»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-thickness-of-shim-s2) .

Note. Overview of components and shims. See SHIMS, POSITION .

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 ADJUSTMENT OVERVIEW - FRONT DIFFERENTIAL table to avoid unnecessary adjustments

ADJUSTMENT OVERVIEW - FRONT DIFFERENTIAL

Shims, position

Note. Adjustment overview when replacing individual components of transmission. See ADJUSTMENT OVERVIEW .

S1 - Adjustment shim for ring gear in cover for differential

S2 - Adjustment shim for ring gear in transmission housing

S3 - Adjustment shim for drive pinion in transmission housing

S4 - Adjustment shim for drive pinion in bearing plate

Scheme 64

Drive pinion, adjusting

Adjusting drive pinion and hollow shaft.

Repairs after which the drive pinion must be adjusted. See ADJUSTMENT OVERVIEW .

Special tools, testers and auxiliary items

1. Universal mandrel VW 385/1
2. Centering disc VW 385/2
3. Centering disc VW 385/3
4. Measuring plunger VW 385/14
5. Dia gauge extension VW385/15
6. Measuring plate VW 385/17
7. Master gauge VW 385/30
8. Universal dial gauge bracket VW 387
9. Press tool VW 407
10. Multi-purpose tool VW 771/15
11. Thrust pad 3062
12. Pin 3114/2
13. Clamping sleeve 3116
14. Bolt 3116/1
15. Torque gauge 0-600 Ncm
16. Dial gauge
17. Dial gauge extension 6.5 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

Scheme 65

Scheme 66

Scheme 67

1. Clamp drive pinion in a vice using clamps -A-.
2. Insert taper rollers with grease, assemble drive pinion and hollow shaft.
3. Turn hollow shaft against drive pinion five turns in both directions so that the taper roller bearings settle.
4. Preload drive pinion/hollow shaft to 10 Nm, hold hollow shaft when doing this.
5. Insert outer race for taper roller bearing for drive pinion into transmission housing without shims. (Scheme 149)and «HEATING GEARBOX HOUSING TO INSERT THE OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__heating-gearbox-housing-to-insert-the).
6. Insert outer race for taper roller bearing for drive pinion with shim "S4*" (1.0 mm thick) into bearing plate. NOTE: For measurement purposes a shim "S4" of 1.0 mm is initially inserted which is designated "S4*" After determining measurement "e" "S4*" will be replaced by the correct shim "S4."
7. Insert completely assembled drive pinion in transmission housing.
8. Fit bearing plate with dowel sleeves and tighten to 25 Nm.
9. Turn drive pinion with hollow shaft five turns in both directions so that the taper roller bearings settle.
10. Assemble measuring equipment, use a 30 mm dial gauge extension.
11. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload. NOTE: The tip of the dial gauge must be positioned on center of drive pinion.
12. Lift drive pinion, without turning, and read off play on dial gauge. Measurement in example: 0.90 mm

Note. If the measurement has to be repeated, the drive pinion with hollow shaft must be turned 5 turns in each direction to settle the taper roller bearings. Set dial gauge again to "0" with 2 mm preload.

Formula

"S total " = "S4*" + measurement + bearing preload

Example

Inserted shim "S4*" 1.00 mm

+ Measured value (example) 0.90 mm

+ Bearing preload (constant) 0.15 mm

= Total shim thickness "S total " for "S3" + "S4" 2.05 mm

Determining thickness of shim "S3*"

Formula

"S3*" = "S total " - "S4*"

Example

Total shim thickness "S total " for "S3" + "S4" 2.05 mm

Inserted shim "S4*" 1.00 mm

= Thickness of shim "S3*" 1.05 mm

1. Remove outer race for taper roller bearing, insert shim "S3*" into transmission housing and install outer race again. (Scheme 149)and «HEATING GEARBOX HOUSING TO INSERT THE OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__heating-gearbox-housing-to-insert-the).
2. Insert completely assembled drive pinion into transmission housing again.
3. Fit bearing plate with dowel sleeves and tighten securing bolts to 25 Nm.
4. Turn drive pinion with hollow shaft five turns in both directions to settle the taper roller bearing.

Determining measurement "e"

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

Scheme 68

Scheme 69

1. Set adjustment rings of universal mandrel VW 385/1 to the following measurements: Dimension a = 65 mm Dimension b = 55 mm
2. Assemble universal mandrel VW 385/1 as illustrated: Dial gauge extension VW 385/15, 9.3 mm long Master gauge VW 385/30
3. Set master gauge VW 385/30 to Ro = 59.65 mm and fit onto mandrel.
4. Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.

Note. The gauge VW 385/27 can also be used in place of the master gauge VW 385/30 (Ro = 59.65 mm).

Arrangement of measuring equipment when determining dimension "e"

Scheme 70

Scheme 71

1. Place end measuring plate VW 385/17 onto drive pinion head. NOTE: Ensure plate contact surface fits exactly and is free of oil.
2. Take master gauge off mandrel.
3. Insert mandrel into transmission housing. The centering disc 385/3 faces towards cover for final drive
4. Fit cover for final drive and tighten 4 bolts to 25 Nm.
5. 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.
6. 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" = 0.16 mm (in red scale)

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" 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

Inserted shim "S3*" 1.05 mm

+ Deviation "r" 0.38 mm

Determined "e" (in red scale) 0.16 mm

= Thickness of shim "S3" 1.27 mm

Determine shim(s) from S3 SHIM THICKNESS AVAILABILITY table.

The following shims are available for "S3"

S3 SHIM THICKNESS AVAILABILITY

Determining thickness of shim "S4"

Formula

"S4" = "S total " - "S3"

Example

Total shim thickness "S total "

for "S3" + "S4" 2.05 mm

Thickness of shim "S3" 1.27 mm

= Thickness of shim "S4" 0.78 mm

Determine shim(s) from table.

The following shims are available for "S4"

S4 SHIM THICKNESS AVAILABILITY

Performing check measurement

Checking dimension "r"

1. Install drive pinion with determined shims "S3" and "S4" and turn 5 turns in both directions.
2. Insert universal mandrel, "determining measurement 'e". See «DETERMINING MEASUREMENT "E"»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__determining-measurement-e) . Perform check measurement.
3. 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 friction 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 "S total " 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.

Scheme 72

1. Fit torque gauge 0-600 Ncm -A- onto drive pinion. B - Socket
2. Insert tensioning sleeve 3116.

Frictional torque specification

FRICTION TORQUE SPECIFICATIONS - FRONT DIFFERENTIAL

Ring gear, adjusting

Adjusting differential.

Repairs after which the ring gear must be adjusted. See ADJUSTMENT OVERVIEW .

Special tools, testers and auxiliary items

1. Drift VW 295
2. Dial gauge extension VW 382/10
3. Measuring plate VW 385/17
4. Universal dial gauge bracket VW 387
5. Measuring lever VW 388
6. Press plate VW 402
7. Installing tool VW 459/2
8. Ring gear adjusting device VW 521/4
9. Attachment for adjusting device VW 521/8
10. Thrust pad 3062
11. Thrust plate 30-205
12. Mandrel 30-505
13. Torque gauge 0-600 Ncm
14. Dial gauge
15. Dial gauge extension
16. Dial gauge extension 30 mm

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

Setting preload of taper roller bearing for differential.

1. Drive pinion removed

Scheme 73

Scheme 74

Scheme 75

1. Remove seal and outer races of both taper roller bearings for differential.
2. Remove shims. (Scheme 183)
3. Drive outer race for taper roller bearing with shim "S2" into transmission housing. For measurement purposes an "S2*" shim 1.20 mm thick (2 shims of 0.60 mm) is used. NOTE: For measurement purposes a shim "S2" of 1.20 mm is initially inserted which is designated "S2*" the following. After determining backlash, "S2*" will be replaced by the correct shim "S2."
4. Press outer race for taper roller bearing without shim "S1" into cover for differential. see scheme 209
5. Insert differential without drive wheel for speedometer sender -G22 into transmission housing. The ring gear is positioned on the left-hand side (same side as cover for final drive).
6. Install cover for differential with 4 bolts (25 Nm).
7. Position transmission so that the cover for differential faces up.
8. Turn differential 5 turns in both directions so that the taper roller bearings settle.
9. Assemble measuring equipment, using a 30 mm dial gauge extension. see scheme 210
10. 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 center of differential. see scheme 210
11. Lift differential, without turning, and read off play on dial gauge. Measurement in following example: 0.62 mm.

Note. Secure special tools VW 521/4 and VW 521/8 on right of differential (transmission side) to lift differential. If the measurement has to be repeated, the differential must again be turned 5 turns in each direction to settle the taper roller bearing.

Scheme 76

Formula

"S total " = "S2*" + measurement + bearing preload

Example

Inserted shim(s) "S2*" 1.20 mm

+ Measured value 0.62 mm

+ Bearing preload (constant) 0.25 mm

= Total shim thickness "S total "

for "S1" + "S2" 2.07 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 "S total " remains unchanged.

Formula

"S1*" = "S total " - "S2"

Example

Total shim thickness "S total "

for "S1" + "S2" 2.07 mm

Inserted shim(s) "S2*" 1.20 mm

= Thickness of shim "S1*" 0.87 mm

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

1. Drive pinion removed

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

Scheme 77

Frictional torque specifications

FRICTIONAL TORQUE SPECIFICATIONS - FRONT DIFFERENTIAL

Note. If the final drive set (drive pinion and ring gear) is being adjusted, perform the adjustment of the drive pinion now and check the adjustment. See DRIVE PINION, ADJUSTING .

Measuring backlash

(Position of ring gear in transmission housing)

1. Drive pinion with shims "S3" and "S4" installed

Scheme 78

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. see scheme 213
4. Insert adjustment device VW 521/4 and VW 521/8 for ring gear. see scheme 213
5. Fit dial gauge with dial gauge extension VW 382/10 (6 mm flat).
6. Set measuring lever VW 388 to dimension a = 79 mm.
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 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 average backlash

1. Add the four measurements together and divide by four.

Example

1st measurement 0.49 mm

+ 2nd measurement 0.48 mm

+ 3rd measurement 0.50 mm

+ 4th measurement 0.49 mm

= Sum of measured values 1.96 mm

1. Result: The average backlash is 1.96 / 4 = 0.49 mm

Determining thickness of shim "S2"

Formula

"S2" = "S2*" backlash + lift

Example

Inserted shim "S2*" 1.20 mm

Average backlash 0.49 mm

+ Lift (constant) 0.15 mm

= Thickness of shim "S2" 0.86 mm

1. Determine shim(s) from «S2 SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

The following shims are available for "S2"

S2 SHIM THICKNESS AVAILABILITY

Determining thickness of shim "S1"

Formula

"S1" = "S total " - "S2"

Example

Total shim thickness "S total " for "S1" + "S2" 2.07 mm

Thickness of shim "S2" 0.86 mm

= Thickness of shim "S1" 1.21 mm

1. Determine shim(s) from «S1 SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) 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 79

Note. If the backlash lies outside the tolerances, the adjustments must be repeated. But the total shim thickness "S total " 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 15° 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»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__repair-instructions) .
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.

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. Hex socket head bolt, 55Nm Self-locking REPLACE bolt The bolt threads in the drive flanges must always be cleaned (for example, with a thread tap).
6. Shim Determining thickness. See «DRIVESHAFT CENTER BEARING SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e)
7. Nut, 25 Nm
8. Stud, 10 Nm Do not remove
9. Transmission

Scheme 80

Scheme 81

Scheme 82

1. Assembly stand 3213
2. Spacers 3139/3

Scheme 83

Scheme 84

Scheme 85

1. Observe notes. See «DRIVESHAFT, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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. Remove heat shield for driveshaft from cover for Torsen 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.

Scheme 86

Note. Driveshaft must always be kept in extended position for transportation and storage.

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

Note. 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. see scheme 223 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, and the colored marking on the driveshaft must be aligned with the marking on the flange. Replace gaskets on drive flanges (pull off backing foil and stick gasket onto flange). 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. Align exhaust system so it is free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: DRIVESHAFT

Special tools and equipment

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

Scheme 87

Procedure

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. See DRIVESHAFT, SERVICING .

Scheme 88

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. Installing drive shaft. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Scheme 89

Scheme 90

1. Assembly stand 3213
2. Spacers 3139/3

Adjusting

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

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Observe notes. See «DRIVESHAFT, SERVICING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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-. see scheme 231
9. Select shims from «DRIVESHAFT CENTER BEARING SHIM THICKNESS AVAILABILITY»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table. The following shims are available DRIVESHAFT CENTER BEARING SHIM THICKNESS AVAILABILITY Distance -a- (mm) Shim thickness (mm) 0-3.0 - 3.1-5.0 2 5.1-7.0 4 7.1-9.0 6 9.1-11.0 8 11.1-13.0 10
10. Install the correct shims on both sides. Install determined adjustment shims as follows
11. 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-.
12. Insert determined adjustment shim -1- and swing bracket for intermediate bearing -2- to other side. see scheme 233
13. Place second adjustment shim -4- onto stud -3-.
14. Now tighten both plastic nuts of installation device -arrow A- again.

Scheme 97

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-). see scheme 234
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-). see scheme 234
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: CENTER BEARING

Oil level in rear final drive, checking

Special tools and equipment

Scheme 98

1. Drip tray V.A.G 1306

Scheme 99

1. Remove plug (arrow) to check oil. see scheme 236 Specification: oil level up to lower edge of filler hole
2. Top-up gear oil if necessary. Specification. See «CODE LETTERS, ALLOCATION, RATIOS AND CAPACITIES»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
3. Fit oil filler plug.

Tightening torque

Oil filler plug: 35 Nm

Special tools, testers and auxiliary items

1. Drift 2062

1. Observe general repair instructions. See «REPAIR INSTRUCTIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__repair-instructions) .

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.

Scheme 100

1. Rear final drive installed

Scheme 101

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 102

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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__oil-level-in-rear-final-drive) .

TIGHTENING TORQUES: DRIVE FLANGE

1. Engine/transmission lift VAG1383A 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 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

1. Rear final drive installed.
2. Observe general repair instructions. See «REPAIR INSTRUCTIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__repair-instructions).
3. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s)). See appropriate Exhaust System article in ENGINES.
4. 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.
5. Unbolt driveshaft from rear final drive and tie up driveshaft to exhaust mounting brackets.
6. Position 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. Carefully lower final drive until the flange is accessible.
9. Mark position of drive pinion retaining nut with paint.
10. In order to check the installation when reassembling, measure and note the following dimensions with depth gauge: Dimension a = distance flange/drive pinion see scheme 244 Dimension b = distance flange/drive pinion nut NOTE: Illustrations show the final drive removed for the following work sequence.
11. Fit counter-hold tool 3028 and remove drive pinion nut.
12. Place drip tray underneath.
13. Pull off flange with special tool VW 391.
14. Screw two M8 x 30 hex bolts -A- into flange.
15. Pull out seal.

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

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

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 hex 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-. see scheme 251 Maximum permissible deviation from original measurements: +0.5 mm
10. Secure hex 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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 from. See «DRIVESHAFT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
2. Aligning exhaust system free of stress. See appropriate Exhaust System article in ENGINES.

TIGHTENING TORQUES: FRONT SUPPORT & DRIVESHAFT

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

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

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.

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

Note. ALWAYS REPLACE self-locking nuts. 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. The threads can be cleaned with a thread tap. REPLACE driveshaft bolts (self-locking). 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. Replace gaskets on drive flange (pull off backing foil and stick gasket to drive flange). To prevent imbalance, the flanges must be installed so that the paint markings arrows -A- and -B- are in alignment. Installing driveshaft. See INSTALLING .

Scheme 122

1. Top up gear oil in rear final drive and check oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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

1. Engine and transmission lift VW 540

Scheme 123

Scheme 124

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

Assembly overview

Note. The following list refers to items in see scheme 263.

1. Final drive housing
2. Spacer sleeve Replace
3. Flange for driveshaft Removing and installing. See «DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__drive-pinion-removing-installing-disassembling-and)
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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__drive-pinion-removing-installing-disassembling-and)
5. Cover for final drive
6. Differential Removing and installing. See «DIFFERENTIAL, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) Disassembling and assembling. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
7. Ring gear Is mated to drive pinion (final drive set) Removing and installing. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Scheme 125

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

Note. The following list refers to items in see scheme 264.

1. Breather sleeve With rubber valve Installation position. See «POSITION OF BREATHER SLEEVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__position-of-breather-sleeve) .
2. Final drive housing 1) Removing and installing drive pinion. See «DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__drive-pinion-removing-installing-disassembling-and) .
3. Outer race for large taper roller bearing 1) Removing and installing. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
4. Shim "S1" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
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 Replacing. See «DRIVE FLANGE OIL SEALS, REPLACING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
8. Hex socket head bolt, 25 Nm
9. Drive flange, right Removing and installing. See «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-and-installing-drive-flange) .
10. Oil filler plug, 35 Nm Checking rear final drive oil level. See «OIL LEVEL IN REAR FINAL DRIVE, CHECKING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__oil-level-in-rear-final-drive) .
11. Differential with ring gear 1) Disassembling and assembling. See «DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
12. Oil drain plug, 35 Nm
13. Bushing 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
16. Shim "S2" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
17. Seal, left Replacing. See «DRIVE FLANGE OIL SEALS, REPLACING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
18. Drive flange, left Removing and installing. See «REMOVING AND INSTALLING DRIVE FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-and-installing-drive-flange) .
19. Hex socket head bolt, 25 Nm
20. Cover Installing. See «PRESS COVER ONTO STOP»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Scheme 126

Removing and installing drive flange

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 127

Position of breather sleeve

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

Scheme 128

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

Scheme 129

1. Collecting pan VAG 1306
2. Rear final drive removed

Scheme 130

1. Secure complete rear final drive on a repair stand with bracket VW 540. See «REAR FINAL DRIVE, SECURING TO REPAIR STAND»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__oil-level-in-rear-final-drive) .

Prepare the following special tools and test equipment

Scheme 131

Scheme 132

Scheme 133

Scheme 134

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

Note. General repair instructions. See REPAIR INSTRUCTIONS . 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 with a " 1) ." See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in see scheme 274.

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 Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
5. Outer race for small taper roller bearing 1) Knocking out. See «KNOCKING OUTER RACE OF SMALL TAPER ROLLER BEARING OUT OF HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Pressing in. See «PRESSING OUTER RACE OF SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING (PRESS TO STOP)»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
6. Inner race for small taper roller bearing 1) Pulling out. See «PULLING OFF INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Pressing in. See «PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
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. See Parts catalog Drive off housing with a punch. See «DRIVING RING GEAR OFF HOUSING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Installing on differential housing. See «INSTALLING RING GEAR»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-off-inner-race-for-large) . Pressing on. See «PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
12. Outer race for large taper roller bearing 1) Driving out «DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Pressing in. See «PRESSING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
13. Shim "S2" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
14. Threaded piece
15. Sun wheel Installing. See «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Adjusting. See «ADJUSTING SUN WHEELS AND PLANET PINIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjusting-sun-wheels-and-planet-pinions) .
16. Planet pinion Installing. See «INSTALLING SUN WHEELS AND PLANET PINIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
17. Planet pinion axis shaft Knock out with drift
18. Shim Re-determining thickness. See «ADJUSTING SUN WHEELS AND PLANET PINIONS»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__adjusting-sun-wheels-and-planet-pinions) .
19. Thrust washer Check for cracks

Scheme 135

Scheme 136

1. After removing check shims for damage.

Scheme 137

Scheme 138

A - Two arm puller, e.g. Kukko 44/2

Scheme 139

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

Pulling off inner race for large taper roller bearing

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

Scheme 140

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

Scheme 141

1. After removing check shims for damage.

Scheme 142

Scheme 143

Scheme 144

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

Scheme 145

Scheme 146

1. If the sun wheels have been replaced, measure and select new shims.
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.

Adjusting sun wheels and planet pinions

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.

Scheme 147

1. Drive in planet pinion axis shaft.
2. Press planet pinions outward.
3. Press sun wheels in direction indicated (arrows), and check the amount of play. see scheme 286
4. Determine the thickest shims for the sun wheels (on each side) which can still just be inserted.
5. Select shims of equal thickness.
6. Identify shims according to the table. Part numbers. See Parts catalog.

The following shims are available

SUN WHEEL SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE

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-. see scheme 287

Scheme 148

Drive pinion, removing, installing, disassembling and assembling

Special tools and equipment

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. Kukko21/7 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 with a "1)". See ADJUSTMENT OVERVIEW .

Note. The following list refers to items in see scheme 288.

1. Nut Removing. See «REMOVING NUT FOR DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-nut-for-drive-pinion) . Installing. See «TIGHTENING NUT FOR DRIVE PINION AND MEASURING FRICTION TORQUE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Measuring friction torque. See «MEASURING FRICTION TORQUE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__measuring-friction-torque) . Securing. See «SECURING DRIVE PINION NUT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__securing-drive-pinion-nut) .
2. Flange for driveshaft Removing. See «PULLING FLANGE FOR DRIVESHAFT OFF DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-flange-for-driveshaft-off-drive) . Installing. See «INSTALLING FLANGE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__installing-flange) .
3. Oil seal Removing. See «PULLING OFF SEAL FOR FLANGE FOR DRIVESHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Driving in. See «DRIVING IN SEAL FOR FLANGE FOR DRIVESHAFT»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-in-seal-for-flange-for) .
4. O-ring Replace Lubricate with transmission oil when installing. See «INSTALLING O-RING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . Installing. See «PRESSING ON SMALL TAPER ROLLER BEARING INNER RACE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
6. Outer race for small taper roller bearing 1) Pulling out. See «PULLING OUT OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pulling-out-outer-race-for-small) . Pressing in. See «PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
7. Spacer sleeve 1) Replace
8. Final drive housing 1)
9. Shim "S3" Note thickness Adjustment overview. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
10. Outer race for large taper roller bearing 1) Driving out. See «DRIVING OUT OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__driving-out-outer-race-for-large) . Pulling in. See «PULLING IN OUTER RACE FOR LARGE TAPER ROLLER BEARING»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-inner-race-for-large-taper) . Pressing on. See «PRESSING INNER RACE FOR LARGE TAPER ROLLER BEARING ONTO DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__pressing-inner-race-for-large-taper) .
12. Drive pinion 1) Is mated with ring gear, always replace together as a set

Scheme 149

Removing nut for drive pinion

1. Screw in two M8 x 30 hex 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 VAG 1359/2 in combination with transmission jack VAG 1383 A).

Scheme 150

Pulling flange for driveshaft off drive pinion

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

Scheme 151

Scheme 152

Scheme 153

Pulling out outer race for small taper roller bearing

1. Counter support e.g. Kukko 22/2
2. Internal puller 46-58 mm, e.g. Kukko 21/7

Scheme 154

Driving out outer race for large taper roller bearing

1. After removing check shims for damage.

Scheme 155

Pressing inner race for large taper roller bearing off drive pinion

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

Scheme 156

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 157

Pulling in outer race for large taper roller bearing

1. First insert predetermined shim "S3" for drive pinion. See «ADJUSTMENT OVERVIEW»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Scheme 158

Note. The marking "Oben" on thrust piece 3253/4 goes toward the nut of the puller.

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

Scheme 159

Scheme 160

1. Insert drive pinion with new spacer sleeve. CAUTION: Wear protective gloves.
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.

Installing O-ring

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

Scheme 161

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 A1.
3. Drive in seal onto stop with drift 3026.

Scheme 162

Installing flange

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

Scheme 163

Scheme 164

1. Screw in two M8 x 30 hex bolts -A-. see scheme 303 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 VAG 1359/2 in combination with transmission jack VAG 1383 A).

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 165

1. The following friction torques should be set.

FRICTION TORQUE - 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Scheme 166

Note. 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. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production. 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. Observe the general repair instructions for taper roller bearings and shims. Maximum care and cleanliness are essential for achieving good results when performing repairs and taking measurements.

Note. The following list refers to items in see scheme 306.

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 167

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 "S total " 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 "S total " for "S1"+ "S2" so that the specified backlash exists between ring gear and drive pinion.

Note. 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. 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 168

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 "S total " for shims "S1"+ "S2". See 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 169

Scheme 170

Scheme 171

1. Mount final drive on repair stand. See «REAR FINAL DRIVE, SECURING TO REPAIR STAND»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .
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.

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").

1. Torque gauge, commercially available, 0-600 Ncm
2. Socket attachment, 36 mm A/F

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

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

1. Tighten drive pinion nut until the following friction torque is obtained. FRICTION TORQUE - REAR FINAL DRIVE New bearings Used bearings (1) 200-250 Ncm 30-60 Ncm (1) Run at least 50 km (30 miles)
2. The final drive must be supported when tightening the nut (for example, using universal transmission attachment VAG 1359/2 in conjunction with transmission jack VAG 1383 A).
3. Set adjustment ring of universal mandrel VW 385/1. Distance -a- = 60 mm. see scheme 313
4. Set sliding adjustment ring. Distance b = 55 mm
5. Assemble universal mandrel as illustrated in see scheme 314. 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 "0" 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.
8. Place end measuring plate VW 385/33 onto drive pinion head.
9. Remove master gauge and insert measuring mandrel in the housing. The centering disc 385/3 faces toward cover for final drive
10. Fit cover for final drive and tighten 4 bolts.
11. Using the adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be turned by hand. Determining measurement "e"
12. 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" = 1.60 mm NOTE: Dimension "e" is required to determine thickness of shim "S3."
13. 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

Measured value "e" 1.60 mm

Deviation "r" 0.42 mm

= Thickness of shim "S3" 1.18 mm

1. Determine shim(s) from «S3 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

The following shims are available for "S3"

S3 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE

1. Remove universal mandrel.
2. Remove drive pinion and outer race of large taper roller bearing and install together with measured shims "S3" and spacer sleeve from. See «REMOVING NUT FOR DRIVE PINION»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e__removing-nut-for-drive-pinion) .
3. 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) . 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.
4. Set to following frictional torques

FRICTIONAL TORQUE - REAR FINAL DRIVE

Checking dimension "r"

Scheme 179

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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

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

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 "S total " 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.

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

Setting preload of taper roller bearing for differential.

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

Scheme 180

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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e).
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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). To perform the measurement use a shim "S2*" with a thickness of 1.00 mm (one 0.80 mm shim and one 0.20 mm shim). NOTE: For measurement purposes a shim "S2" of 1.0 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/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e). 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. see scheme 320 Dial gauge extension approx. 30 mm long Hex 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.

Scheme 181

Formula

"S total " = "S2*" + measurement + bearing preload

Inserted shim(s) "S2" 1.00 mm

+ Measured value 0.50 mm

+ Bearing preload (constant) 0.30 mm

= Total shim thickness "S total "

for shims "S1" + "S2" 1.80 mmm

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 "S total " remains unchanged.

Formula

"S1*" = "S total " - "S2*"

Example

Total shim thickness "S total "

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. See «S1 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) .

Measuring frictional torque (check)

1. Drive pinion removed
2. Differential fitted with shims "S1*" and "S2*"
3. Fit torque gauge 0-600 Ncm -A- onto differential.
4. Read off frictional torque.

Frictional torque specifications

FRICTIONAL TORQUE - REAR FINAL DRIVE DIFFERENTIAL

Scheme 182

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 "S total " 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 readjusted, 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 183

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. see scheme 323
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. 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 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 1.16 / 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 «S2 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

The following shims are available for "S2"

S2 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE

Determining thickness of shim "S1"

Formula

"S1" = "S total " - "S2"

Example

Total shim thickness "S total " 1.80 mm for "S1" + "S2"

Thickness of shim "S2" 0.86 mm

= Thickness of shim "S1" 0.94 mm

1. Determine shim(s) as accurately as possible from «S1 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE»(/audi/s6/c5-1999-2004/remont/differentials-drive-axles/#6-spd-manual-transmission-01e) table.

The following shims are available for "S1"

S1 SHIM THICKNESS AVAILABILITY - REAR FINAL DRIVE

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

Scheme 184

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

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

See also:
• TOWING
• CHECKING FLUID LEVEL
• CODE LETTERS, ALLOCATION, RATIOS, AND CAPACITIES
• OIL LEVEL IN REAR FINAL DRIVE, CHECKING
• BEARING HOUSING, TORSEN DIFFERENTIAL AND END COVER, REMOVING AND INSTALLING
• GEAR CLUSTER AND SELECTOR SHAFT, REMOVING AND INSTALLING
• DIFFERENTIAL, REMOVING AND INSTALLING
• BEARING HOUSING, DISASSEMBLING AND ASSEMBLING
• BEARINGS FOR TORSEN DIFFERENTIAL, SERVICING
• 5TH AND 6TH GEAR, REMOVING AND INSTALLING
• INPUT SHAFT, DRIVE PINION, HOLLOW SHAFT AND INTERNAL SELECTOR MECHANISM FROM BEARING PLATE, REMOVING AND INSTALLING
• SELECTOR SHAFT (COMPLETE), DISASSEMBLING AND ASSEMBLING
• TRANSMISSION HOUSING, SERVICING
• INSTALLING
• BEARING PLATE, SERVICING
• PULLING BALL SLEEVE OUT OF FOLLOWER FOR REVERSE GEAR
• INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
• DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING
• PRESSING OUT DRIVE FLANGE
• PRESSING IN DRIVE FLANGE
• PREPARING SEAL FOR INSTALLATION
• DRIVING IN SEAL
• 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
• PULLING CYLINDER ROLLER BEARING FOR INPUT SHAFT OUT OF END COVER
• PRESSING CYLINDER ROLLER BEARING FOR INPUT SHAFT FLUSH INTO 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
• PULLING NEEDLE BEARING FOR TORSEN DIFFERENTIAL OUT FROM END COVER
• DRIVING NEEDLE BEARING FOR TORSEN DIFFERENTIAL FLUSH INTO END COVER
• PRESSING IN OUTER RACE FOR SMALL TAPER ROLLER BEARING
• ADJUSTMENT OVERVIEW
• SHIM "S4," RE-DETERMINING
• MEASURING INSERTION DEPTH OF CYLINDER ROLLER BEARING FOR INPUT SHAFT
• REMOVING AND INSTALLING BALL SLEEVES FOR SELECTOR RODS
• CHECKING SYNCHRO-RING FOR WEAR
• DETERMINING SHIM WHEN REPLACING HOLLOW SHAFT
• AVAILABLE SHIMS FOR "S4"
• REPAIR INSTRUCTIONS
• PULLING OUT SEAL FOR DRIVE FLANGE
• DRIVING IN SEAL FOR DRIVE FLANGE
• LEVERING OUT SEAL FOR INPUT SHAFT WHEN TRANSMISSION IS DISMANTLED
• DRIVING IN SEAL FOR INPUT SHAFT
• REMOVING SEAL FOR INPUT SHAFT WHEN TRANSMISSION IS NOT DISMANTLED
• PULLING OUT BALL SLEEVE
• DRIVING IN BALL SLEEVE
• 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
• REMOVING CIRCLIP
• PULLING NEEDLE BEARING OUT OF TRANSMISSION HOUSING
• DRIVING NEEDLE BEARING INTO TRANSMISSION HOUSING
• INSERTION DEPTH OF NEEDLE BEARING
• INSERTION DEPTH OF BREATHER SLEEVE FOR TRANSMISSIONS WITHOUT BREATHER HOSE
• BREATHER FOR TRANSMISSION WITH BREATHER HOSE
• PULLING OUT SEAL FOR SELECTOR SHAFT
• DRIVING IN SEAL FOR SELECTOR SHAFT
• INSTALLING SEAL AND SELECTOR SHAFT WITH ASSEMBLY SLEEVE
• INSTALLATION POSITION OF OIL BAFFLE PLATE ONLY FOR TRANSMISSION WITH TRANSMISSION OIL COOLER
• SPEEDOMETER SENDER -G22- AND DRIVE WHEEL FOR SPEEDOMETER SENDER, REMOVING AND INSTALLING
• DRIVING OUT AND DRIVING IN ROLL PIN FLUSH
• DRIVING OUT SELECTOR SHAFT
• DRIVING IN SELECTOR SHAFT
• INSERTING SPRING IN SLIDING GEAR
• RE-DETERMINING THICKNESS OF CIRCLIP
• SYNCHRO-HUB INSTALLATION POSITION
• PRESSING ON SYNCHRO-HUB FOR 3RD AND 4TH GEAR
• DRIVING SPRING PIN INTO INPUT SHAFT
• END COVER, SERVICING
• 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 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
• REMOVING AND INSTALLING CIRCLIP FOR SYNCHRO-HUB AND SHIM FOR 1ST SPEED SLIDING GEAR
• 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
• RING GEAR, ADJUSTING
• DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
• PULLING INNER RACE FOR SMALL TAPER ROLLER BEARING OUT OF HOUSING
• INSTALLING RING GEAR
• PULLING INNER RACE FOR LARGE TAPER ROLLER BEARING OFF HOUSING
• DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER
• DETERMINING TOTAL SHIM THICKNESS "STOTAL" FOR SHIMS "S1" + "S2"
• DETERMINING THICKNESS OF SHIM "S3"
• DETERMINING THICKNESS OF SHIM "S2"
• SHIMS, POSITION
• DRIVE PINION, ADJUSTING
• MEASURING BACKLASH
• DETERMINING MEASUREMENT "E"
• DRIVESHAFT, SERVICING
• DRIVE PINION, REMOVING, INSTALLING, DISASSEMBLING AND ASSEMBLING
• POSITION OF BREATHER SLEEVE
• REMOVING AND INSTALLING DRIVE FLANGE
• PULLING OFF INNER RACE FOR LARGE TAPER ROLLER BEARING
• ADJUSTING SUN WHEELS AND PLANET PINIONS
• REMOVING NUT FOR DRIVE PINION
• 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
• PULLING OUT 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 OFF DRIVE PINION
• ADJUSTING BACKLASH