Servicing - M/t (6 Speed, 01e) Audi S6 C5

TRANSAXLE

The code letters of the transmission are engraved on the lower part of the transmission cover and are also engraved on the vehicle data plates. For identification locations on transaxle, see list below.

1. Code letters and consecutive serial numbers (arrow 1). (Scheme 1)
2. Manual transmission 01E (arrow 2). (Scheme 2)

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

Scheme 1

Scheme 2

SERVICE INTERVALS

No oil changes are required.

CHECKING FLUID LEVEL

Note. When checking the oil level in the transaxle, the vehicle should be standing on a perfectly horizontal surface. An inspection pit or a 4-post lifting platform is ideal. The prescribed oil level is to be adhered to exactly; the transmission reacts very sensitively to over-filling.

Note. If a transmission with transmission oil cooling has been removed, the vehicle must be driven a short distance on the road before checking the transmission oil level.

Check oil level in transaxle. Remove oil filler plug (B), (in front of drive flange) to check transmission oil level. (Scheme 3)

Check oil level with a suitable tool (such as a length of wire bent to shape). Vehicles without oil cooler: oil level should be 0.276" +/-.039" (7 mm +/- 1 mm) below bottom lip of oil filler hole. Vehicles with oil cooler: oil level should be 1mm below bottom lip of oil filler hole. Fill up with gear oil if necessary. Gear Oil Specification: SAE 75 W 90 (synthetic oil), Part number G 00 500 0. Fit oil filler plug and tighten to 30 ft. lbs. (40 N.m). (Scheme 3)

Scheme 3

RECOMMENDED FLUID

Manufacturer recommends SAE 75W-90. Part number G 005 000 (1 liter), a synthetic gear oil.

FLUID CAPACITIES

TRANSMISSION REFILL CAPACITIES

BATTERY DISCONNECT PRECAUTIONS

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

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

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

ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)

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

OnStar(R) Emergency Battery: Switching Off

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

OnStar(R) Emergency Battery: Switching On

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

Adjustment

The following points are essential to ensure correct selector adjustment

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

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. Shift cover is removed together with the cover for center console. Unscrew shift knob from shift lever. Slightly lift off cover for center console upward (arrows -A-). (Scheme 4) Pull cover slightly toward back (arrow -B-), then lift complete cover upward. (Scheme 4)
2. Remove noise insulation cover for shift mechanism housing (arrows). (Scheme 5)
3. Measure distance between body and rear push rod (in selector mechanism). Specification: distance a = 1.69" (43 mm). (Scheme 6)
4. If that is not the case, obtain distance (a) as follows: Loosen bolt (arrow) for pivot rod. (Scheme 6)
5. Rear pivot rod (in shift control mechanism) must move freely back and forth on sliding piece. Adjust measurement (a) by moving pivot rod rear (in shift control mechanism). (Scheme 6) Tighten bolt for pivot rod to 18 ft. lbs. (25 N.m).
6. Loosen bolt for selector rod (arrow). (Scheme 7) Connection between selector rod and selector mechanism should move freely.
7. Adjust gear shift as follows: Gear shift vertical, maximum inclination of 3° to the right (angle a). (Scheme 8)
8. Gear shift inclined slightly backwards (approx. 7°, angle b). (Scheme 9) The illustration shows the gear shift from the right. Hold gear shift in this position. Tighten selector rod bolt to 18 ft. lbs. (25 N.m).

Scheme 8

1. Please note the following points: The gear shift lever must rest in the 3rd/4th gear gate when transaxle in neutral. Check operation of 1st and 2nd gear stop. Engage 2nd gear and push gear shift to the left against the stop. Reduce pressure on gear shift until it moves back to pressure point. Spring-back measured at gear shift handle: 0.118"-0.197" (3-5 mm). Check that all gears can be engaged. Check operation of reverse gear lock. It should only be possible to engage reverse gear after pressing the gear shift down to overcome the reverse gear lock. It must be possible to move the gear shift, without pushing and without force, forwards from the reverse gear lock to the 3rd/4th gear plane.
2. If the gear shift setting is incorrect it can be adjusted as follows: Loosen bolt for selector rod (arrow). (Scheme 7)
3. Move gear shift to the left or to the right until distance (x) is 0.33" (8.5 mm). (Scheme 10) Hold gear shift in this position. Tighten selector rod bolt to 18 ft. lbs. (25 N.m).
4. Check gear shift setting again. Fit covers and gear shift knob.

REMOVAL & INSTALLATION

AXLE SEALS

Note. This procedure is performed with transmission installed.

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

Scheme 9

1. Remove heat shield. Disconnect drive axle shaft from transmission. Place a drip tray underneath.
2. Remove drive flange, secure with a drift to prevent it turning. Pull seal out with lever VW 681. (Scheme 11)

Installation

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

1. Fill space between sealing and dust lips with sealing grease G52 128 A1. Lightly oil outer circumference of seal. Drive in seal for drive flange. Pressing-in depth (factory): 5.5 mm. (Scheme 12) Pressing-in depth when re-installing a used drive flange (repairs): 6.5 mm. Install drive flange and drive axle.

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 and Shim, Part No. 016 311 391 B

Removal

To identify drive flange and bearing housing components. (Scheme 13)

Scheme 10

Note. This procedure is performed with transmission installed.

Scheme 11

Scheme 12

Scheme 13

1. Disconnect driveshaft at the front, lift clear and tie-up on selector linkage. Place a drip tray underneath. Unscrew rear oil drain plug (on end cover) and drain transmission oil.
2. Unscrew securing bolts for bearing housing. If the bearing housing is not pressed off: Pull drive flange together with bearing housing and balance weight off end cover. (Scheme 14) A - M8/M10 stud. Take off bearing housing.
3. Remove circlip from flanged shaft. Press out flanged shaft. (Scheme 15)
4. Pull out flanged shaft seal. (Scheme 16) Thoroughly clean seat for seal.
5. Press out grooved ball bearing. (Scheme 17)

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Press grooved ball bearing in bearing housing. (Scheme 18)
2. Lightly oil outer circumference of seal -B-. Fill space between sealing lips and dust lips with sealing grease G52 128 A1. Fit seal with shim -A-, Part No. 016 311 391 B (1.7 mm thick) onto punch 2005. Installation position: Open side of seal toward transmission. (Scheme 19)
3. Drive in drive flange seal. see scheme 20 Remove washer after inserting seal.
4. Press in drive flange. see scheme 21 Fit circlip onto drive flange. Lightly oil O-ring and fit into bearing housing groove. Insert spring plate and shims into bearing housing. Concave side of dished washer must face shims. Slide coil spring onto drive flange. see scheme 21
5. Tighten securing bolts for bearing housing in diagonal sequence and in stages to 25 Nm.
6. Bolt on driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01E (AWD TRANSAXLE)»(ref-172270).
7. 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).

SHIFT MECHANISM

To identify shifter mechanism components. (Scheme 20)and (Scheme 21).

Scheme 18

Scheme 19

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

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Unscrew shift knob from shift lever. Slightly lift off cover for center console upward (arrows -A-). (Scheme 22) Pull cover slightly toward back (arrow -B-), then lift complete cover upward. NOTE: Shift cover is removed together with the cover for center console.
2. Remove noise insulation cover for shift mechanism housing (arrows). (Scheme 23)
3. Unscrew nuts securing shift mechanism housing (arrows). (Scheme 24)
4. Remove heat shield for left-hand inner joint -1- from transmission (arrows). (Scheme 25) Detach left-hand drive axle -1-, lift toward the front and tie up. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s).
5. Remove heat shield above driveshaft. Remove heat shield for driveshaft from cover for Torsen differential (arrows). (Scheme 26)
6. Remove driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01E (AWD TRANSAXLE)»(ref-172270).
7. Unscrew support bracket bolts -1- and -2- on left and right. (Scheme 27)
8. Lower subframe at the rear. Dimension -a- = max. 50 mm. (Scheme 28)
9. Nut (arrow -B-) and Bolt (arrow -C-) must be removed to remove shift rod. (Scheme 29)
10. Unbolt connecting rod -2- on right-hand side of transmission. see scheme 32 Remove hex socket head bolt from push rod -1-. see scheme 32
11. Unscrew nut -1- and pull selector rod lever -2- off transmission selector shaft. see scheme 33 Swing gear shift housing with selector rod and push rod down and remove.

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

1. Install in reverse order of removal, noting the following: Install driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01E (AWD TRANSAXLE)»(ref-172270) .
2. Adjust driveshaft. See «DRIVESHAFT & UNIVERSAL JOINTS - 01E (AWD TRANSAXLE)»(ref-172270) .
3. Adjust gear selector mechanism. See «SHIFT LEVER MECHANISM»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e) .
4. Align exhaust system free of stress.

VEHICLE SPEED SENSOR

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

Pull connector off sender -B-. see scheme 34 Press sender retainer down, turn and pull out sender.

Handle sender carefully. Replace O-ring -A-. If it is damaged it is possible that the speedometer will not indicate exactly.

Scheme 26

VEHICLE SPEED SENSOR DRIVE WHEEL

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

Scheme 27

1. Detach drive axle from left drive flange -B-. see scheme 35 Unscrew bolt -A-. see scheme 35 Secure drive flange with a drift to prevent it turning.
2. Remove drive flange and seal -C-. see scheme 35 Using a screwdriver, lever out drive wheel for speedometer sender -D- on alternate sides at the follower lugs (arrows). see scheme 35

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

1. Install drive wheel for vehicle speed sensor so that follower lugs (arrows) face toward seal. see scheme 35 Follower lugs engage in differential housing grooves.
2. Replace seal for drive flange and install drive flange. See «AXLE SEALS»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e__axle-seals).
3. Check transmission oil level. Top off to lower edge of fill hole, if necessary. See «LUBRICATION»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e). Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/manual-trans/#servicing-mt-6-speed-01e).

Scheme 28

Scheme 29

See also:
• ONSTAR(R) EMERGENCY BATTERY (AUDI TELEMATICS)
• BATTERY DISCONNECT PRECAUTIONS
• TORQUE SPECIFICATIONS
• CHECKING FLUID LEVEL
• AXLE SEALS