Manual-6Vel-0B1.pdf

Edition 10.2010

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - front differential


Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Audi Q5 2008 2008 ➤ 6-speed manual gearbox 0B1, front-wheel drive - Edition 10.2010

1.1 1.1 1.2 1.2 1.3 1.3

Expl Explod oded ed view view - peda pedall clus cluste terr (LHD (LHD vehi vehicl cles es)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remo Removi ving ng and and inst instal alli ling ng over over-c -cen entr tre e spri spring ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remo Removi ving ng and and ins insta tall llin ing g clu clutc tch h ped pedal al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 3.2 3.2 3.3 3.3 3.4 3.4 3.5 3.5

Notes Notes on removi removing ng and and instal installin ling g clutch clutch maste masterr cylind cylinder er and and slave slave cylin cylinder der . . . . . . . . . . . . 15 Func Functi tion on chec check k for for clut clutch ch mast master er cyli cylind nder er and and slav slave e cyli cylind nder er . . . . . . . . . . . . . . . . . . . . . . 16 Remo Removi ving ng and and ins insta tall llin ing g clu clutc tch h mas maste terr cyl cylin inde derr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rene Renewi wing ng clut clutch ch slav slave e cyl cylin inde derr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Blee Bleedi ding ng clut clutch ch syst system em . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.1 4.1

Tigh Tighte teni ning ng sequ sequen ence ce - clu clutc tch h mod modul ule e to to dri drive ve plat plate e . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .

25

2.1 2.1 2.2 2.2

Remo Removi ving ng and and inst instal alli ling ng gear gear knob knob with with gear gear leve leverr boot boot . . . . . . . . . . . . . . . . . . . . . . . . . . Remo Removi ving ng and and ins insta tall llin ing g noi noise se insu insula lati tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 30

3.1 3.1 3.2 3.2

Remo Removi ving ng and and inst instal alli ling ng sele select ctor or mech mechan anis ism m . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. Adju Adjust stin ing g sel selec ecto torr mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 36

4.1 4.1 Copying Remo Refor movi ving ngorgear ge arbo box x purposes, – vehi vehicl cles wi thwhole, 4-cy 4-cyli nder er dies diesel el engi engine ne Protected by copyright. private commercial ines partwith or in islind not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 4.2 Instal Installin ling g gearb gearbox ox – vehicl vehicles es with with 4-cyli 4-cylind nder er diesel diesel engin engine e with respect to the correctness of information in this document. Copyright by AUDI A G.

. . .. . .. . .. . .. . .. . .. . .. . . . .. .. .. .. .. .. .. .. .. .. .. .

7 8 11

39 48

5.1 5.1 5.2 5.3 5.3

Remo Removi ving ng and and ins insta tall llin ing g tun tunne nell cro cross ss memb member er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Removi Removing ng and and instal installin ling g gearb gearbox ox suppo support rt with with gea gearb rbox ox mounti mounting ng . . . . . . . . . . . . . . . . . . . . 60 Remo Removi ving ng and and inst instal alli ling ng gear gearbo box x mou mount ntin ing g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.1

Renewi Renewing ng oil seal seal for for flang flange e shaf shaftt (rig (rightht-sid side) e) with with gea gearb rbox ox insta installe lled d . .. .. .. .. .. .. .. .. . Contents

72

i



ii

Contents


♦ Alloca Allocatio tion, n, Aud Audii Q5 2008 2008 ► ⇒ „2 Code letters, allocation, transmission ratios, capacities“, page 2

♦ -Arro -Arrow w A- Manu Manual al gearb gearbox ox 0B1 0B1 ⇒ page 1 ♦ -Arrow -Arrow B- Code Code letter letters s and prod productio uction n date ⇒ page 1 ♦ -Arrow -Arrow C- Code letter letters s and product production ion date date on undersid underside e of gearbox housing (not on all versions)

Code le letters

Production da date: 29.09.2010

♦ Additional data data are manufacturemanufacture-related. related. ♦ The code letters for the gearbox are also given on the vehicle data stickers.


1. Gearbox identification

1


♦ Date Date of of manu manufa fact ctur ure e ♦ Gear Gear oil oil spe specif cifica icatio tion n ♦ Indivi Individu dual al gear gear ratio ratios s ♦ Corre Correct ct type type of of flang flange e shaft shafts s ♦ Correct Correct type of dualdual-mass mass flywheel flywheel ♦ Correct Correct type type of clutch clutch plate plate and and pressu pressure re plate plate ♦ Correct Correct type of rear rear final final drive accord according ing to code code letters letters and PR number

Code letters Allocation

Ratio

Model Engi Engine ne Final drive Intermediate drive

Capacity

LYK

NAF

Audi Q5 2008 2008 ► 2.0 2.0 ltr ltr.. TDI TDI - 100 100 kW 2.0 ltr. TDI - 105 kW

Audi Q5 2008 2008 ► 2.0 ltr. TDI - 100 kW 2.0 ltr. TDI - 105 kW

29 : 8 = 3.625

29 : 8 = 3.625

35 : 31 = 1.129

35 : 31 = 1.129 4.3 ltr.


2

Rep. gr.00 - Technical data


Arrows point point in direction of of travel.

❑ With With nee needl dle e bea beari ring ng for for gearbox input shaft ❑ Cons Consis ists ts of pres pressu sure re Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not plate, clutch plate and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability dual-mass flywheel with respect with to the correctness of information in this document. Copyright by AUDI A G. flange for drive plate

❑ With With beve bevelo loid id teet teeth h

3. Transmission layout

3


Proper tools and the maximum possible care and cleanliness are essential for satisfactory repairs to the transmission units. The usual basic safety precautions precautions also naturally apply when carrying out repair work. A number of generally generally applicable instructions for for the various various re‐ pair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They ap‐ ply to the work described in this Manual.

For a complete list of special tools used in this Workshop Manual ⇒ Workshop equipment and special tools .

♦ Servicin Servicing g ⇒ Servicin Servicing g 6-speed 6-speed manua manuall gearbox gearbox 0B1, front front-wheel drive; Rep. gr. 34 ♦ Allocate Allocate bolts bolts and other other component components s according according to gearbox gearbox code letters, refer refer to ⇒ Electronic parts parts catalogue ⇒ „2 Code letters, allocation, transmission ratios, capacities“, page 2 . 2 . ♦ When insta installing lling a new new gearbox gearbox,, check the the oil level level and fill fill up with oil if necessary ⇒ page 61 . 61 . ♦ Capaci Capacitie ties s and specifi specificat cation ions s ⇒ page 2 ♦ Thoroughly Thoroughly clean all joints and connections connections and the the surround‐ surround‐ ing areas before dismantling. ♦ When installing gearbox ensure dowel sleeves are correctly correctly seated.

♦ Thoroug Thoroughly hly clean clean joint surfaces surfaces on gearbo gearbox x housing housing etc. be‐ fore applying sealing paste. ♦ Apply Apply sealing sealing paste paste -AMV -AMV 188 001 001 02- evenly evenly and and not too too thickly. ♦ Breather Breather holes holes must must remain remain free free of sealin sealing g paste. paste.

♦ Always Always renew renew O-rin O-rings, gs, seals seals and and gaske gaskets. ts. ♦ After removi removing ng gaskets gaskets and seals, seals, always always inspect inspect the contact contact surface on the housing or shaft for burrs resul ting from removal or for other signs of damage. ♦ Thoroughly Thoroughly clean clean housing joint surfaces before assembling. assembling. ♦ Before installing oil seals, seals, lightly lightly oil the outer outer circumference circumference of the seal and fill the space between the sealing lips -arrowabout half full with grease -G 052 128 A1- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

does not or ntaining accept any liability ♦ Thepermitted open open unless side side authorised of the oil oibyl AUDI sealAG. should shAUDI ouldAGface face the theguarantee side contai co ning with respect to the correctness of information in this document. Copyright by AUDI A G. the fluid.

♦ When insta installing lling a new new oil seal, seal, positio position n the seal seal such that that the sealing lip does not contact the shaft in t he same place as the old seal (make use of installation depth tolerances). ♦ Lightly Lightly lubricate lubricate O-ring O-rings s before before installatio installation n to prevent prevent them from being trapped and damaged during assembly. ♦ After renew renewing ing gaskets gaskets and and oil seals, seals, check and, and, if necessar necessary, y, top up oil level in gearbox ⇒ page 61 . 61 .

4



♦ Do not not over-s over-stre tretch tch circ circlip lips. s. ♦ Always Always renew renew circlips circlips which have have been been damaged damaged or overoverstretched. ♦ Circlips Circlips must must be properl properly y seated seated in the base base of the the groove. groove. ♦ Renew Renew spring spring pins. Positio Position: n: the slit -A-A- should should be in line with with the line of force -arrow-.

♦ Loosen Loosen the nuts nuts and bolts bolts in reverse reverse sequenc sequence e to the specifie specified d tightening sequence. ♦ Nuts and and bolts bolts which secure secure cover covers s and housin housings gs should should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified. ♦ Loosen and tighten particularly sensitive parts in diagonal diagonal se‐ quence and in stages, taking care to keep them straight. ♦ The tighten tightening ing torques torques stated stated apply apply to non-oil non-oiled ed nuts and and bolts. ♦ Always Always renew renew selfself-locki locking ng bolts bolts and and nuts. nuts. ♦ Use a wire wire brush brush to clean clean the threads threads of of bolts which which are are se‐ cured with locking fluid. Then apply locking fluid AMV 185 101 101 A1- to bolt bolt threads before before installing. installing. ♦ Threade Threaded d holes holes which take take self-locki self-locking ng bolts bolts or bolts coated coated with locking fluid flu id must be cleaned (using a tap or similar). Oth‐ erwise there is a danger of the bolts shearing off the next time they are removed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ When removi removing ng gearbox, gearbox, remove remove clutch clutch slave cylinde cylinderr without without disconnecting pipes. ♦ Do not depre depress ss the clutch clutch pedal pedal after after removing removing the the clutch slave slave cylinder if the hydraulic pipe is still connected. connected. Otherwise the piston will be pressed out of the clutch slave cylinder. As a result the clutch slave cylinder will be destroyed. ♦ If the clutch clutch pedal pedal does does not return return to its its initial initial position position after after releasing it - clutch pedal in rest position-, you must bleed the clutch system. Further measures ⇒ „3.1 Notes on removing and installing clutch master cylinder and slave cylinder“, page 15 . 15 . ♦ If the clutch clutch has burnt burnt out, thorou thoroughly ghly clean clean the gearbo gearbox x hous‐ ing in area of clutch and parts of the engine facing the gearbox in order to prevent odours. ♦ Blow out out clutch clutch module module with compr compresse essed d air only. only. ♦ The brake brake fluid fluid in the clutch clutch system system should should be change changed d at the same intervals as the brake fluid in the brake system ⇒ Main‐ tenance ; Booklet 405 ; Description Descripti on of work; Brake fluid: changing (every 2 years) .

4. General repair instructions

5



6



⇒ „1.1 Exploded view - pedal cluster (LHD vehicles)“, page 7 ⇒ „1.2 Removing and installing over-centre spring“, page 8 ⇒ „1.3 Removing and installing clutch pedal“, page 11 ⇒ „2 Exploded view - pedal cluster (RHD vehicles)“, page 12 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

⇒ „3 Exploded view - clutch hydraulics“, page 14 AG does not guarantee or accept any liability permitted unless authorised by AUDI AG. AUDI with respect to the correctness of information in this document. Copyright by AUDI A G.

⇒ „3.1 Notes on removing and installing clutch master cylinder and slave cylinder“, page 15 ⇒ „3.3 Removing and installing clutch master cylinder“, page 17 ⇒ „3.4 Renewing clutch slave cylinder“, page 20 ⇒ „3.5 Bleeding clutch system“, page 22

♦ Apply grease grease -G 000 450 450 02- to all all bearings bearings and contact sur‐ sur‐ faces. ♦ Make sure that no brake fluid escapes into the footwell, the plenum chamber or onto the gearbox below. If this does hap‐ pen, clean the affected area thoroughly.

1. Servicing clutch mechanism

7


❑ With With brak brake e ped pedal al ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 17

❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 11

❑ For For clut clutch ch mas maste terr cyli cylin‐ n‐ der

❑ Loca Locate ted d in clut clutch ch ped pedal al ❑ Blac Black k sid side e poi point nts s to‐ to‐ wards clutch pedal ❑ Note Note dif diffe fere rent nt bea beari ring ng positions in mounting bracket ⇒ page 10 ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 8 ❑ For For corr correc ectt vers versio ion, n, re‐ re‐ fer to ⇒ Electronic parts catalogue ❑ Note Note dif diffe fere rent nt bea beari ring ng positions in mounting bracket ⇒ page 10 ❑ Renew


❑ Removing and installing installing ⇒ page 17 ❑ Clutch pedal pedal switch -F36-F36- and clutch pedal pedal switch for engine start -F194-F194- are integrated integrated ❑ Can only only be renewe renewed d together together with with clutch clutch master master cylind cylinder er ⇒ Item 11 (page 8)

8

Rep. gr.30 - Clutch


♦ Assem Assembly bly clip clip -T40 -T4002 0255-

♦ Remova Removall wedge wedge -3409 -3409--

– Remove dash dash panel trim (driver's side) side) ⇒ Rep. gr. 68 .


– Remove footwell footwell vent (left-side) (left-side) ⇒ Rep. gr. 87 .


9


– Move clutch pedal pedal -1- slightly slightly in direction of -arrow-. -arrow-. Press as‐ as‐ sembly clip -T40025- onto over-centre spring -2- while overcentre spring is compressed. – Depress clutch pedal fully to stop and remove remove over-centre over-centre spring downwards with assembly clip.


– Clip bearing bearing shell -1- into into appropriate appropriate bearing bearing position. position.

•

„I“ -arrow A-:

♦ 2.0 ltr. 120/125 kW TDI-Motor ♦ 2.0 2.0 ltr ltr.. TFS TFSII engi engine ne

•

„II“ -arrow B-

♦ 1.8 ltr. TFSI engine ♦ 2.0 ltr. ltr. 88 88 kW kW TDI TDI eng engine ine ♦ 2.0 ltr. ltr. 100 100 kW TDI engin engine e ♦ 2.0 ltr. ltr. 105 105 kW TDI engin engine e

– Insert over-centre over-centre spring spring -2-. •

Black Black side side -arro -arrow w C- face faces s clutch clutch pedal pedal..

– Depress clutch pedal -1- fully to stop and install over-centre over-centre spring -2- with assembly clip -T40025- . – Pull clutch pedal pedal back to rest rest position. Take assembly clip off off over-centre spring while over-centre spring is compressed.

– Install footwell vent vent ⇒ Rep. gr. 87 . – Install dash panel panel trim (driver's (driver's side) ⇒ Rep. gr. 68 .

10

Rep. gr.30 - Clutch


– Remove mounting mounting bracket bracket ⇒ Brake system; Rep. Rep. gr. 46 ; Removing and installing mounting bracket (vehicles with man‐ ual gearbox) . – Remove over-centre over-centre spring spring -2- ⇒ page 8 . 8 .

– Remove locking locking pin -1-. – Remove pivot pin -2- by lifting retaining tab -arrow A- and turn‐ ing pivot pin in direction of -arrow B-. – Pull out pivot pivot pin -2- and remove clutch clutch pedal -3-. -3-.

Installation is carried out in reverse sequence; note the following: – Apply grease grease -G 000 450 450 02- to all all bearings bearings and contact sur‐ sur‐ faces. – Install clutch pedal -3-, push in pivot pin -1- and lock in direction of -arrow A-. Bottom of retaining tab -2- should engage at pedal bracket. – Insert locking pin -4-. Shoulder Shoulder on pin pin -arrow B- must be in‐ troduced into groove on clutch pedal. – Install over-centre over-centre spring spring ⇒ page 10 . 10 . – Install mounting mounting bracket ⇒ Brake system; Rep. Rep. gr. 46 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.


11


♦ Apply grease grease -G 000 450 450 02- to all all bearings and and contact sur‐ sur‐ faces. ♦ Make sure that no brake fluid escapes into the footwell, the plenum chamber or onto the gearbox below. If this does hap‐ pen, clean the affected area thoroughly.

❑ For For clut clutch ch mas maste terr cyli cylin‐ n‐ der

❑ Note Note dif diffe fere rent nt bea beari ring ng positions in clutch pedal ⇒ page 10


❑ Blac Black k sid side e poi point nts s to‐ to‐ wards clutch pedal ❑ Note different bearing bearing positions in clutch pedal ⇒ page 13 ❑ For For corr correc ectt vers versio ion, n, re‐ re‐ fer to ⇒ Electronic parts catalogue

❑ Renew

❑ Clut Clutch ch peda pedall swi switc tch hF36- and clutch pedal switch for engine start F194- are integrated ❑ Can only only be renewe renewed d together together with with clutch clutch master master cylind cylinder er ⇒ Item 13 (page 12)

12

Rep. gr.30 - Clutch


❑ With With brak brake e peda pedall

❑ 2x ❑ 8 Nm

– Clip bearing bearing -1- into correspond corresponding ing position on clutch pedal. pedal.

•

„I“ -arrow A-:

♦ 2.0 ltr. TFSI engine ♦ 2.0 ltr. ltr. 120 120 kW TDI engin engine e ♦ 2.0 ltr. ltr. 125 125 kW TDI engin engine e

•

„II“ -arrow B-

♦ 1.8 ltr. TFSI engine ♦ 2.0 ltr. ltr. 88 88 kW kW TDI TDI eng engine ine ♦ 2.0 ltr. ltr. 100 100 kW TDI engin engine e ♦ 2.0 ltr. ltr. 105 105 kW TDI engin engine e


2. Exploded view - pedal cluster (RHD vehicles)

13


Observe notes on removing and installing clutch master cylinder and slave cylinder ⇒ page 15 . 15 .

❑ Do not not ope opera rate te clut clutch ch pedal after slave cylin‐ der has been removed ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 20 ❑ Afte Afterr work workin ing g on hy‐ hy‐ draulic clutch mecha‐ nism, bleed clutch sys‐ tem ⇒ page 22 ❑ Do not not allo allow w bra brake ke flui fluid d to come into contact with gearbox. ❑ 5.5 Nm ❑ Foll Follow ow corr correc ectt pro proce ce‐‐ dure when bleeding ⇒ page 22 ❑ If blee bleede derr scr screw ew has has broken off, it can be re‐ moved with 3 mm Allen key

❑ With With fre frequ quen ency cy mod modul ula‐ a‐ tor ❑ For For plu plugg-in in conn conne ections on clutch master cylin‐ der and slave cylinder ❑ Conn Connec ecti ting ng and and dis disco con‐ n‐ necting ⇒ page 15 ❑ Allo Alloca cati tion on for for LHD LHD and and RHD vehicles vehicles ⇒ Elec‐ tronic parts catalogue

❑ Rene Renew w ifif dam damag aged ed ❑ Lubricate with brake fluid brake fluid before installing ❑ For clutch clutch maste masterr cyli cylind nder er Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ With With integ integrat rated ed seali sealing ng gro gromme mmets ts permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability torommets the correctness of information indthis document. Copyright by AUDI AG. ❑ Renew Renew supply supply hose hose if with sealing searespect ling grom g mets are are damage damaged

❑ To remove remove pipe/hos pipe/hose e assembly assembly,, pull out out clip as far as as stop ⇒ page 15 . 15 . ❑ Removi Removing ng and instal installin ling g ⇒ page 17

14

Rep. gr.30 - Clutch

Audi Q5 2008 2008 ➤ 6-speed manual gearbox 0B1, front-wheel drive - Edition 10.2010 ❑ After workin working g on hydrauli hydraulic c clutch mechan mechanism, ism, bleed bleed clutch clutch system system ⇒ page 22 ❑ Conne Connecti cting ng and and disc discon onne necti cting ng ⇒ page 15 ❑ For correct correct versi version, on, refer refer to ⇒ Electron Electronic ic parts parts catal catalogu ogue e ❑ For pipe ❑ Atta Attach ched ed to gear gearbo box x ❑ 20 Nm ❑ Rene Renew w ifif dam damag aged ed ❑ Lubricat Lubricate e with with brake brake fluid before before insta installing lling ❑ To remove remove pipe/hose pipe/hose assembly assembly,, pull out out clip as far as stop ⇒ page 15 . 15 . ❑ 20 Nm

– Release retaining retaining clip -A-A- using a screwdriver screwdriver and and pull out to limit stop. – Pull off pipe/hose pipe/hose assembly. assembly.

Renew O-ring if damaged. – Press retaining retaining clip -A- in as far as it will go. go. – Push pipe/hose pipe/hose assembly into into connection connection until until it engages engages au‐ au‐ dibly. – Pull on pipe/hose pipe/hose assembly assembly to check it is secure. secure.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI A G.

♦ Before Before renewin renewing g the clutch clutch master master cylinder cylinder or slave slave cylinder cylinder on the assumption that it is defective, you must first carry out the appropriate function check ⇒ page 16 . 16 . ♦ If the slave slave cylinder cylinder is remov removed ed from from gearbox gearbox with with the pipe/ pipe/ hose assembly still attached, make sure you do not press the clutch pedal. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. ♦ After install installing ing the slave slave cylinde cylinderr carefully carefully press press the clutch clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down fur‐ ther. The plunger of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

3. Exploded view - clutch hydraulics

15


Before you renew the clutch master cylinder or slave cylinder you must - in the case of the following faults - first carry out the ap‐ propriate checks.

♦ First First check the overover-cent centre re spring spring / clutch pedal pedal switch switch for noise. ♦ If you hear hear a noise, noise, remove remove over-cen over-centre tre spring spring and and repeat repeat check. ♦ Renew Renew relev relevan antt compo compone nent. nt.

♦ Check Check whether whether the clutch clutch pedal pedal return returns s all the way to its its initial initial position, thereby uncovering the vent opening in the master cylinder. ♦ Check Check that footwell footwell trim trim and/or and/or floor floor mats are not not trapped trapped and and that clutch pedal switch is not blocked. ♦ Make the the custome customerr aware aware that the the driver driver must NOT NOT rest his/ his/ her foot on the clutch pedal for long periods of time. ♦ This could could impair impair the self-b self-bleed leeding ing function function of of the clutch clutch sys‐ tem as the vent opening in the clutch master cylinder can no longer function. ♦ The vent vent opening opening must be be uncovered, uncovered, otherwise the perma‐ perma‐ nent self-bleeding function for the hydraulic clutch system will no longer be effective. ♦ The vent vent opening opening is integra integrated ted in the clutch clutch master master cylind cylinder. er. It is not visible from the outside.

♦ Check Check brake brake fluid level level in brake brake fluid fluid reserv reservoir. oir. ♦ Check Check clutch maste masterr cylinder cylinder and and slave cylind cylinder er as well well as the pipe/hose assembly including connections for external leaks (visual inspection). inspection). ♦ If you identi identify fy any leaks leaks you must must renew renew the leakin leaking g compo‐ compo‐ nent. ♦ Blee Bleed d clut clutch ch sys syste tem m ⇒ page 22 . 22 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unlessl authorised AUDI AG. AUDI AG not guarantee accept any liability ♦ Mechanical Mechanica fault fault onbyclutch plate or does pressure plateor ⇒ Servicing with respect to the correctness of information in this document. Copyright by AUDI A G. 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 30

♦ approx. approx. 140 140 N for complet complete e service service life of of the clutch clutch

♦ Air in hydra hydraulic ulic system system:: bleed bleed clutch clutch system system ⇒ page 22 and 22 and check hydraulic system for external and internal leaks. ♦ Clutch Clutch plate plate does does not run smoot smoothly hly on input input shaft shaft splines splines ♦ Needle bearing in drive drive plate plate defective defective (centring (centring bearing for input shaft); renew needle bearing ⇒ Rep. gr. 13 . ♦ Forei Foreign gn bod body y in clutc clutch h system system

16

Rep. gr.30 - Clutch


♦ Mechanic Mechanical al fault fault on clutch clutch plate plate or pressu pressure re plate plate ⇒ Servicing Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 30 ♦ Wrong Wrong component components s used or compone components nts forgotte forgotten n when car‐ rying out repair work (e.g. intermediate plate or dowel sleeves between engine and gearbox).

♦ Hose Hose clamp clamp,, up to to 25

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability respect to the correctness of information in this document. Copyright by AUDI A G. mm mm -3094 -3with 094-

♦ Open Open ring ring spanner spanner,, 32 mm -3355-3355-

– Observe notes notes on removing removing and installing installing clutch master master cyl‐ inder and slave cylinder ⇒ page 15 . 15 .

– Disconnect battery battery ⇒ Rep. gr. 27 .


17


– Remove electronics electronics box ⇒ Electrical system; system; Rep. gr. 97 .

In the following steps make sure that no brake fluid escapes into the plenum chamber or onto the gearbox below. If this does hap‐ pen, clean the affected area thoroughly. – Clamp off supply hose -2- from brake fluid reservoir using hose clamp -3094- . Disconnect hose from clutch master cylinder -1- and plug hose. – Release retaining retaining clip -3-3- using a screwdriver screwdriver and and pull out to limit stop. – Pull off pipe/hose pipe/hose assembly assembly -4-.

Leave connector -item 5- connected. – Remove over-centre over-centre spring spring ⇒ page 8 . 8 . – Pull locking pin pin -1- out of clutch clutch pedal -3-. -3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability withand respect to the correctness information in this document. Copyright by AUDI AG. -Item 2-arrows A, B- ofcan be disregarded.

18

Rep. gr.30 - Clutch


– Release clutch clutch master cylinder cylinder in direction direction of -arrow-arrow- using open ring spanner, 32 mm -3355- .

– Pull out clutch master cylinder cylinder -1- and guide it out through through opening for engine wiring harness. – Release connector connector -5- and unplug. unplug.

– Plug in connector connector -5-. – Install clutch master master cylinder -1-.

– Pull clutch master master cylinder into into footwell in direction direction of -arrow A-. At the same time lock clutch master cylinder in di‐ rection of -arrow B- using open ring spanner, 32 mm -3355- .


– Insert locking pin -4-. Shoulder Shoulder on pin pin -arrow B- must be in‐ troduced into groove on clutch pedal.

-Items 1, 2, 3- and -arrow A- can be disregarded. – Install over-centre over-centre spring spring ⇒ page 10 . 10 .


19


– Press in retaining retaining clip -3-3- as far as stop. – Insert pipe/hose pipe/hose assembly assembly -4- into clutch master cylinder cylinder and make sure that it engages audibly. – Pull on pipe/hose pipe/hose assembly assembly to check it is secure. secure. – Slide on supply supply hose -2- as far as stop. – Remove hose hose clamp -3094-3094- . – Bleed clutch system system ⇒ page 22 . 22 . – Install electronics electronics box ⇒ Rep. gr. 97 . – Observe correct correct procedure procedure after connecting connecting battery battery ⇒ Rep. gr. 27 .

♦ Torqu Torque e wren wrench ch -V.A. -V.A.G G 1331 1331--

♦ Engine Engine bung bung set set -VAS -VAS 6122 6122-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Safe Safety ty gog goggl gles es

20

Rep. gr.30 - Clutch


– Observe notes notes on removing removing and installing installing clutch master master cyl‐ inder and slave cylinder ⇒ page 15 . 15 .

Do not allow brake fluid to come into contact with the gearbox. If necessary, clean the gearbox housing. – If fitted, remove rear noise insulation -2-2- ⇒ Rep. gr. 66 .

– Release retaining retaining clip -2-2- using a screwdriver screwdriver and and pull out to limit stop. – Disconnect hose hose from clutch slave cylinder and plug hose. hose. – Remove bolt bolt -3- and pull pull out clutch slave slave cylinder -1-1- to the rear.

Seal off open lines and connections with clean plugs from engine bung set -VAS 6122- to prevent dirt from entering.

Installation is carried out in reverse sequence; note the following:

♦ Renew O-ring if damaged. ♦ If the clutch slave cylinder is inserted at Copying an angle, there is a purposes, in part or in whole, is not Protected by copyright. for private or commercial unless AUDI AG. AG does not guarantee or accept any liability danger that the operatingpermitted rod will beauthorised guidedbypast theAUDI clutch with respect to the correctness of information in this document. Copyright by AUDI AG. release lever.


21


– When installing, installing, press in clutch clutch slave cylinder cylinder -1- so that that se‐ curing bolt -3- can be fitted easily. Tightening torque ⇒ Item 17 (page 15) – Press in retaining retaining clip -2-2- as far as stop. – Push hose/pipe hose/pipe assembly assembly into clutch slave cylinder until it en‐ en‐ gages audibly. – Pull on pipe/hose pipe/hose assembly assembly to check it is secure. secure. – Bleed clutch system system ⇒ page 22 . 22 . – Install rear rear noise insulation (if originally originally fitted) fitted) ⇒ Rep. gr. 66 .

♦ Brake Brake filling filling and bleed bleeding ing equipm equipment ent -VAS -VAS 52345234-

♦ Brake Brake fluid specifica specification tion ⇒ Rep. gr. 47 .

♦ The clutch system must be bled after performing work on the hydraulic clutch mechanism. copyright. for private or commercial purposes, in part or in whole, is not ♦ When performing the following steps, stepsProtected , makebysure thatCopying no brake permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability fluid escapes onto the gearbox. with respect to the correctness of information in this document. Copyright by AUDI A G.

♦ Before bleeding the clutch system, pull back the clutch pedal to the normal position and top up brake fluid to „Max“ marking on brake fluid reservoir. ♦ Open the bleeder screw before switching on the bleeding ap‐ pliance. ♦ The brake fluid in the clutch system should be changed at the same intervals as the brake fluid in the brake system ⇒ Main‐ tenance ; Booklet 405 ; Description Descripti on of work; Brake fluid: changing (every 2 years) .

22

Rep. gr.30 - Clutch


– Connect brake filling and bleeding equipment equipment -VAS 5234- , but do not switch on at this stage ⇒ Brake system; Brakes - hy‐ draulics; Rep. gr. 47 ; Bleeding brake system . – If fitted, remove rear noise insulation -2-2- ⇒ Rep. gr. 66 .


– Connect bleeder bleeder hose -A- to clutch slave slave cylinder and and open bleeder screw -arrow-. – Connect bleeder hose to pressure hose of fluid collector bottle. – Switch on bleeding appliance and allow about 100 cm 3 of brake fluid to drain out. •

Oper Operat atin ing g pre press ssur ure e 2.0 2.0 bar bar

Ensure bleeder hose is correctly fitted during bleeding operation. – Tighten bleeder bleeder screw. screw. Tightening torque ⇒ Item 2 (page 14) – Depress clutch pedal several several times after bleeding process process is completed. – Repeat bleeding bleeding procedure procedure if necessary. necessary. – Install rear noise insulation insulation ⇒ Rep. gr. 66 .


23


Servicing clutch module -2- ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 30 ; Servicing clutch

❑ Not Not fitt fitted ed in in all all vehi vehicl cles es ❑ When When clut clutch ch modu module le -2-2is bolted onto drive plate -1-, locating pins -A- (if provided) must engage in locating holes -B❑ When When clut clutch ch modu module le -2-2is bolted onto drive plate -1-, locating pins -A- (if provided) must engage in locating holes -B-

❑ 4-cy 4-cyli lind nder er engi engine ne:: 3 holes with threaded sleeves ❑ 6-cyli 6-cylind nder er or 8-cyli 8-cylind nder er engine: 6 holes with threaded sleeves ❑ With With need needle le bear bearin ing g ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ Engine, mechanics; Rep. gr. 13 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ With With flan flange ge for drive drive plate plate ❑ Componen Components: ts: dual-mas dual-mass s flywheel, flywheel, clutch clutch plate and clutch clutch pressure pressure plate plate ❑ Removing and installing ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel front-wheel drive; drive; Rep. Rep. gr. gr. 30 ; Removing and installing clutch module ❑ Servicing ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel front-wheel drive; drive; Rep. Rep. gr. gr. 30 ; Servicing clutch ❑ ❑ ❑ ❑ ❑

24

60 Nm Secures Secures dual-ma dual-mass ss flywhe flywheel el to to drive drive plate plate 4-cy 4-cyli lind nder er eng engin ine: e: 3x 3x 6-cyli 6-cylind nder er or 8-cy 8-cylin linde derr engine engine:: 6x Alw Always ays ren renew Rep. gr.30 - Clutch

Audi Q5 2008 2008 ➤ 6-speed manual gearbox 0B1, front-wheel drive - Edition 10.2010 ❑ Follow Follow corre correct ct tighte tightenin ning g sequen sequence ce ⇒ page 25

♦ Ring spann spanner er insert, insert, 16 16 mm -V.A.G -V.A.G 1332 1332/14/14-

•

Use new bolts.

•

Tigh Tighte teni ning ng torq torque ue ⇒ Item 3 (page 24)

•

Tighten Tighten bolts bolts using using ring ring span spanner ner insert, insert, 16 16 mm -V.A.G -V.A.G 1332/14- .

– Engage 6th 6th gear by pulling pulling out selector selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.


The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant. – Turn both front wheels together in one direction until the clutch module has turned through one complete revolution (360°). •

The inspe inspection ction hole hole -arro -arroww- should should be be visible visible again again in the re‐ re‐ cess on the gearbox housing.

4. Exploded view - clutch module

25


– Install first bolt -arrow-arrow- and and tighten hand-tight hand-tight (2 Nm). Nm). – Turn both front wheels so that clutch module turns 120° further in direction of engine rotation and install second sec ond bolt hand-tight (2 Nm). – Turn clutch module 120° further in direction direction of engine engine rotation. – Then screw in in and tighten tighten third bolt. – Now tighten the the remaining remaining two bolts to specified specified torque. torque.

– Install first bolt -arrow-arrow- and and tighten hand-tight hand-tight (2 Nm). Nm). – Turn both front wheels so that clutch module turns 180° further in direction of engine rotation. – Now install second second bolt and tighten to specified specified torque. torque. – Now install remaining remaining bolts all round, round, and tighten immediately immediately to specified torque (also tighten the first bolt installed).


26

Rep. gr.30 - Clutch


•

For a detaile detailed d descrip description tion please please refer refer to the Works Workshop hop Man‐ ual ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. Rep. gr. 30 ; Servicing Servicing clutch .

•

For a detaile detailed d descrip description tion please please refer refer to the Works Workshop hop Man‐ ual ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 30 ; Exploded view - clutch release mecha‐ nism .


5. Clutch, clutch release mechanism

27


⇒ „2 Exploded view - gear knob with gear lever boot“, page 29 ⇒ „2.1 Removing and installing gear knob with gear lever boot“, page 29 ⇒ „2.2 Removing and installing noise insulation“, page 30 ⇒ „3 Exploded view - selector mechanism“, page 32 ⇒ „3.1 Removing and installing selector mechanism“, page 33 ⇒ „3.2 Adjusting selector mechanism“, page 36


28

Rep. gr.34 - Controls, housing


❑ With With gear gear leve leverr boo boott ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 29 ❑ Secu Secure res s gea gearr kno knob b to to gear lever ❑ Secu Secure re with with hose hose clip clip pliers -V.A.G 1275-


❑ Only Only sup suppl plie ied d toge togeth ther er with support ring ⇒ Item 4 (page 29) ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 30 together 30 together with noise insulation ⇒ Item 5 (page 29) ❑ Only Only sup suppl plie ied d toge togeth ther er with boot ⇒ Item 3 (page 29) ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 30

❑ 8 Nm ❑ For For gea gearr leve leverr bear bearin ing g

The gear knob is removed together with the gear lever boot.

2. Exploded view - gear knob with gear lever boot

29


♦ Remova Removall wed wedge ge -3409 -3409--

♦ Hose Hose clip clip pliers pliers -V.A -V.A.G .G 127 12755-


– Prise out gear gear lever boot boot using removal removal wedge -3409-arrows- and pull upwards to detach.

– Pull boot up and over gear gear knob. – Open clip -arrow-arrow- and and pull off gear gear knob together together with boot. boot.

Installation is carried out in reverse sequence; note the following: – Secure clip -arrow-arrow- using using hose clip pliers pliers -V.A.G 12751275- .

– Switch off ignition. ignition. – Remove gear gear knob with gear gear lever boot boot ⇒ page 29 . 29 .

30



– Remove multimedia system operating operating unit -E380-E380- ⇒ Rep. gr. gr. 91 .

– Release retaining retaining tabs -1- in direction direction of -arrow-. -arrow-. At the same time, lift rear end of noise insulation slightly. – Pull noise insulation insulation out of of tabs -3-. – Pull boot -2-2- off gear lever lever in direction direction of -arrow-. -arrow-.


– Insert noise insulation into into tabs -1- and and press down down until re‐ taining tabs -2- engage. – Pull boot over over gear lever lever and into rounded rounded groove groove -arrow -arrow A-. – Press support support ring in boot boot over gear gear lever bearing bearing as far as as stop in direction of -arrow B-. – Install multimedia multimedia system operating operating unit unit -E380- ⇒ Rep. gr. 91 . – Install gear knob with gear gear lever boot boot ⇒ page 29 . 29 .

2. Exploded view - gear knob with gear lever boot

31


❑ Take Take out out bef befor ore e rem remov ov‐‐ ing ball

❑ Do not grease ❑ Do not grease ❑ For For gea gearr leve leverr bea beari ring ng ⇒ Item 11 (page 32) ❑ Do not grease ❑ 23 Nm ❑ Do not grease Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Bend Bend poin points ts towa toward rds s rear ❑ Appl Apply y gre greas ase e to to gui guide de and gear lever stops if necessar y; y; grease ⇒ Electronic parts cata‐ logue

❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 33 ❑ Do not grease ❑ Betwee Between n select selector or rod rod and and gear gear lever lever ❑ Apply Apply grease grease ifif necessar necessary; y; grease grease ⇒ Electron Electronic ic parts parts catalo catalogue gue ❑ For For join jointt body body ⇒ Item 12 (page 32) ❑ 23 Nm ❑ 10 Nm

❑ With With bolt bolt and and was washe her r ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 33 ❑ For correct correct versi version, on, refer refer to ⇒ Electron Electronic ic parts parts catal catalogue ogue

32



❑ 20 Nm ❑ Renew ❑ 4 Nm ❑ Install Install so that that gap in splines splines align aligns s with selec selector tor shaft shaft ❑ Apply Apply grease grease ifif necessa necessary; ry; grease grease ⇒ Electron Electronic ic parts parts catalo catalogue gue

❑ Apply Apply grease grease ifif necessa necessary; ry; grease grease ⇒ Electron Electronic ic parts parts catalo catalogue gue ❑ To rem remove ove pull pull off reta retaini ining ng clip clip ⇒ Item 26 (page 33) . 33) . ❑ To rem remove ove pull pull off reta retaini ining ng clip clip ⇒ Item 26 (page 33) . 33) . ❑ 20 Nm

❑ 20 Nm

•

Push rod -1- is bolted bolted to left left side side of gearbo gearbox x cover. cover.

♦ Pull Puller er -T40 -T4016 1600Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Exploded view - selector mechanism

33


– Switch off ignition. ignition. – Remove gear gear knob with gear gear lever boot boot ⇒ page 29 . 29 . – Remove air conditioner conditioner operating operating and display unit ⇒ Rep. gr. gr. 87 .

– Remove multimedia system operating operating unit -E380-E380- ⇒ Rep. gr. gr. 91 .

–

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Remove front fron t ashtray -1- ⇒ Rep. gr. 68in .this document. Copyright by AUDI AG. with respect to the correctness of information

– Remove noise noise insulation above selector selector mechanism mechanism ⇒ page 30 . 30 . – Remove nuts nuts -arrows-.

34



– Remove noise noise insulation (rear) -2-2- ⇒ Rep. gr. 66 .

– Remove bolt bolt -1- for push push rod and bolt -3- for connecting connecting rod. rod.

-Item 2- can be disregarded.

– Remove nut nut -1-.

-Item 2- can be disregarded. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

– Apply puller puller -T40160-T40160- and pull off gearbox selector selector lever. lever.


35


– Remove nuts nuts -arrows- and and detach heat heat shield -1-. -1-. – Take out selector selector mechanism mechanism towards rear. rear.

Installation is carried out in reverse sequence; note the following: •

Tigh Tighte teni ning ng torq torque ues s ⇒ page 32 and 32 and ⇒ page 29 . 29 .

– Install heat heat shield below below selector selector mechanism mechanism ⇒ Rep. gr. 66 . – Install rear noise noise insulation insulation ⇒ Rep. gr. 66 . – Adjust selector mechanism ⇒ page 36 . 36 . – Install multimedia multimedia system operating operating unit unit -E380- ⇒ Rep. gr. 91 . – Install air conditioner conditioner operating operating and and display unit unit ⇒ Rep. gr. 87 .

The following are prerequisites for correct gear lever alignment: •

Gear Gear selector selector linka linkage ge must must be in prop proper er conditio condition n and unda undam‐ m‐ aged.

•

Select Selector or mech mechan anism ism must must move move fre freely ely..

•

Gearbox Gearbox,, clutch clutch and and clutch clutch mechan mechanism ism must must be in prope properr con‐ con‐ dition.

•

Protected Gear Gearbo box x in in neu neutr tral al.. by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness the correctness of information i nformation in this document. Copyright by AUDI AG.

– Remove gear gear knob together together with boot boot ⇒ page 29 . 29 . – Remove noise noise insulation above selector selector mechanism mechanism ⇒ page 30 . 30 . – Check adjustment adjustment of push rod: rod: dimension dimension -x-. •

Specif Specifica icatio tion: n: dist distan ance ce -x- = 25 25 mm mm

– If distance measured measured is not not correct, adjust adjust dimension -x-x- as follows: – Loosen bolt bolt -arrow- for for push rod. rod. •

The gear gear lever lever bear bearing ing should should move move freely freely in in both both direction directions s on slide

– Set dimension dimension -x- by moving moving gear lever lever bearing. bearing. – Tighten bolt bolt for push rod rod -arrow- in that position. position. Tightening torque ⇒ Item 7 (page 32)

36



– Slacken off bolt bolt for selector rod rod -arrow-. -arrow-. •

Connectio Connection n betwee between n selector selector rod and selec selector tor mecha mechanism nism should move freely.

– Position bottom bottom of gear lever lever in centre of gear lever lever bearing. bearing. •

Distance Distance betwee between n gear gear lever lever bearing bearing and botto bottom m of gear gear lever lever -arrows- must be the same at all points.

– Align gear lever so that itit points slightly (3.5°) (3.5°) to the right right (as seen in direction of travel). – Hold gear lever in this position. position.



37


– Tighten bolt bolt for selector rod rod -arrow-. -arrow-. Tightening Tightening torque ⇒ Item 14 (page 32)

The gear lever must remain in the same position while the bolt is being tightened.

– Start engine. engine. – Press clutch pedal. pedal. – Select all gears gears severalProtected times. times.by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AU DI AG. AUDI AG AG does not guarantee or accept any liability

with respect to the correctness information in this document. Copyright by AUDI AG. – Operate reverse reverse gear gear detent (press (press gear lever leverof downwards) downwa rds) and move gear lever all the way to the left into reverse gear gate.

– Now move gear gear lever forwards forwards and engage engage reverse reverse gear. gear.

Do not exert any sideways pressure on the gear lever while en‐ gaging reverse. – Check that reverse reverse gear has has actually been been engaged, engaged, and not not 1st gear. •

If 1st gear gear has has been been engag engaged ed instea instead d of rever reverse, se, the the gear gear lever lever is set too far to the left. Correct the adjustment adjustment ⇒ page 37 . 37 .

– Disengage reverse gear. gear. – Now engage engage 2nd gear, gear, but at the same same time exert exert increased pressure towards the left. •

If the gear gear lever lever sticks sticks when when engag engaging ing 2nd 2nd gear, gear, it is set set too far to the right. Correct the adjustment ⇒ page 37 . 37 .

♦ It should only be possible to engage reverse gear after press‐ ing the gear lever down to overcome the reverse gear detent. ♦ The gear lever should return by itself from the reverse gear gate to the 3rd/4th gear gate. ♦ If the gear lever sticks or baulks repeatedly when engaging a gear, perform the adjustment procedure again ⇒ page 37 . . – Install noise insulation insulation ⇒ page 30 . 30 . – Install gear knob knob together together with boot ⇒ page 29 . 29 .

38



⇒ „4.1 Removing gearbox – vehicles with 4-cylinder diesel en‐ gine“, page 39 ⇒ „4.2 Installing gearbox – vehicles with 4-cylinder diesel engine“, page 48

♦ Suppo Support rt brac bracket ket -10 -10 - 222 A♦ Ring Ring span spanner ner insert insert,, 16 mm -V.A.G 1332/14♦ Engin Engine e and and gea gearbo rbox x jack jack V.A.G 1383 A♦ Stepla Stepladd dder er -VAS -VAS 50855085♦ Pull Puller er -T40 -T4016 1600♦ Gear Gearbo box x suppo support rt -T40 -T4017 1733-


4. Removing and installing gearbox

39


♦ Relea Release se tool tool -T40 -T4013 1388-


– Bring wheels wheels into straight-ahead straight-ahead position. position. – Switch off ignition ignition and take out out ignition key. – Disconnect battery battery ⇒ Rep. gr. 27 .

– Carefully detach detach engine cover panel panel from retaining retaining studs in direction of -arrow-. Pull out engine cover panel evenly, with‐ out jerking.

40



– Remove noise noise insulation panels -1- and -2- ⇒ Rep. gr. 66 .

– Detach noise insulation -1-1- from wheel wheel housing (both (both sides).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised AUDI AG. AUDI does not guarantee or accept any liability – Remove nuts nutsbyfor front exhaust exhAG aust pipe -arrows-. -arrows-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Disconnect exhaust system at clamp -arrows- and detach front exhaust pipe.


41


– Unfasten bolted bolted connection connection -1-.

– Remove body body brace ⇒ Rep. gr. 40 . – Remove air cleaner housing housing ⇒ Rep. gr. 23 .

– Unscrew nuts -1, 2 and and 3- on turbocharger turbocharger and tie up particu‐ particu‐ late filter.

– Remove engine/gear engine/gearbox box securing bolts -2 … 6-. 6-.


42



♦ Bolts -3- and -5- also secure brackets for pipes and/or wiring. Tie these brackets onto the engine. ♦ Bolt -2- secures starter to gearbox. A spacer sleeve is located between starter and gearbox -arrow-.

– Install body brace brace and attach attach to engine engine lifting eye with ten‐ sioning strap -T10038- , as shown in illustration. – Tighten tensioning tensioning strap. strap.

– Remove bolt bolt -arrow- for for universal joint joint ⇒ Rep. gr. 48 . – Press universal universal joint joint off steering steering box and push push all the way up. by copyright. Copying for private or commercial purposes, in part or in whole, is not –Protected Remove nut nut -1- for hydraulic hydraulic fluid pressure pressure line for power permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability steering. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove bolts bolts -arrows- and and detach subframe subframe cross cross brace.


43


– Engage 6th 6th gear by pulling pulling out selector selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.

– If fitted, unplug electrical connector -2- at engine speed sender -G28- and move electrical wiring clear on gearbox.


– Pull cover -1-1- off bottom of of gearbox -arrow-. -arrow-.

– Remove 3 bolts bolts -arrow-arrow- for drive plate plate (turn both both front wheels wheels so that crankshaft rotates 120° in direction of engine rotation each time).


44



– Remove bolts bolts -arrows- and and detach heat heat shield for for drive shaft (right-side).

– Unbolt drive shafts (left and right) from flange shafts on on gear‐ box.


– Unclip electrical electrical wire -A- from from gearbox gearbox -arrows-. -arrows-.

– Unclip bracket -B- with electrical connector -C- for exhaust gas temperature sender 4 -G648- from gearbox and tie up.

– Remove bolts bolts -1- and -3-. -3-.


45


– Disconnect electrical electrical connector connector -arrow-arrow- from gear gear detector switch -F208- using release tool -T40138- and move electrical wiring clear.

– Unplug electrical electrical connector connector from gearbox gearbox neutral neutral position sender -G701- -1- and move wiring clear.

– Unscrew bolt -2-, -2-, detach pipe pipe from bracket bracket and pull pull clutch slave cylinder off gearbox. – Tie clutch slave cylinder up to the side in engine compartment. compartment.



– Apply puller -T40160-T40160- and pull off off gearbox selector selector lever -1-.

46



– Place used oil oil collection and and extraction unit -V.A.G 17821782- be‐ low connection. – Remove bolts -arrows-, detach hydraulic line -1- from steering box and place to one side.

Seal off open lines and connections with clean plugs from engine bung set -VAS 6122- to prevent dirt from entering.

– Remove bolt bolt -1- for starter. starter. – Detach starter starter from gearbox gearbox but do not not remove starter. starter.

Starter cables do not have to be disconnected. – Remove remaining remaining engine/gea engine/gearbox rbox securing securing bolts -7 … 10-. 10-.

– Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- underneath gearbox and secure with ten‐ sioning strap -1- as shown in illustration.

Make sure no electrical wiring is trapped when attaching tension‐ ing strap.

– Remove bolts bolts -arrows- for for tunnel cross cross member. – Detach gearbox gearbox from engine engine and lower lower carefully carefully using using engine engine and gearbox jack -V.A.G 1383 A- .

♦ When lowering gearbox, make sure that all wires are discon‐ nected on the top of the gearbox. ♦ When lowering gearbox, make sure there is sufficient clear‐ ance from drive shafts.



47


– If the removed removed gearbox gearbox is being replaced, replaced, the following following com‐ ponents must be transferred to the replacement gearbox:

♦ Bracket Bracket -1- for exhaust exhaust system system mounti mounting ng ⇒ Rep. gr. 26 . ♦ Tunnel Tunnel cross membe member, r, gearbox gearbox mountin mounting g and gearbox gearbox sup‐ port ⇒ page 58 . 58 . ♦ Remove Remove clutch clutch modul module e if necessa necessary ry ⇒ Servicin Servicing g 6-spee 6-speed d manual gearbox 0B1, front-wheel drive; Rep. gr. 30 ; Remov‐ ing and installing clutch module .

♦ Assemb Assembly ly aid -T40 -T40169 169--

♦ Transpor Transportatio tation n lock -T40170 -T40170--


48



♦ Renew bolts which are tightened by turning through a speci‐ fied angle. The aluminium bolts securing the engine to the gearbox can be used twice only. ♦ Renew self-locking nuts and bolts, and seals, O-rings and gaskets. ♦ Hose connections and air pipes and hoses must be free from oil and grease before fitting. ♦ Secure all hose connections with the correct hose clips (as original equipment); refer to ⇒ Electronic parts catalogue . ♦ To ensure that the charge air hoses can be connected se‐ curely, you must spray the screws on used screw-type clips with rust remover prior to installation. ♦ Re-attach all cable ties at the same locations when re-instal‐ ling.

– Position gearbox gearbox on gearbox gearbox support support -T40173-T40173- and secure secure with tensioning strap -1-, as shown in illustration.


– Check the input input shaft for scoring scoring around around the bearing bearing in the drive plate -arrow-. Renew the needle bearing in the driv e plate if necessary ⇒ Rep. gr. 13 .


49


– Install clutch module module if previously previously removed removed ⇒ Servicing 6speed manual gearbox 0B1, front-wheel drive; Rep. gr. 30 ; Removing and installing clutch module .

– The following following preparations preparations must be made before before joining the the engine and gearbox: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Insert assembly aid -T40169-T40169 inthe tocorrectness gearbox gearboxof housing and clutch Copyright by AUDI AG. with respect-tointo information in this document. module from below, as shown in illustration. •

The assem assembly bly aid aid -T4016 -T401699- must must engag engage e in the the semi-c semi-circu ircular lar recess -1- and in the inspection hole -2-.

There is only one inspection hole at the periphery; turn the clutch module accordingly. – Insert pin of assembly assembly aid into into hole on gearbox gearbox housing. housing.

– Insert transportation transportation lock -T40170-T40170- into gearbox gearbox housing from below and clamp onto flange shaft -1-.

50



– Check that dowel dowel sleeves -A- for centralising centralising engine/gearbox engine/gearbox are in the cylinder block; install any missing dowel sleeves.

Items -1 ... 10- can be disregarded.

– Raise gearbox gearbox just far enough to be able to insert insert clutch slave cylinder. – Tighten bolt bolt -2-. Tightening Tightening torque torque ⇒ Item 17 (page 15)

•

Check Check whether whether aluminiu aluminium m bolts bolts -2 … 10- can be be reused reused for engine/gearbox connection and mark bolts if necessary ⇒ page 57 . 57 .

– Join gearbox gearbox with engine and and tighten tighten bolts -7 … 10-. 10-. Tighten‐ ing torques ⇒ page 57 – Fit starter and and install bolt -1-1- from engine engine side hand-tight. hand-tight. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

– Clip bracket -B-B- with electrical electrical connector -C- for exhaust exhaust gas temperature sender 4 -G648- onto gearbox. – Secure electrical electrical wire -A- on gearbox gearbox -arrows-. -arrows-.


51


– Install gearbox gearbox selector lever lever -2- as follows: follows: •

Gearbox Gearbox selec selector tor lever lever -2-2- can only only be fitted fitted onto selector selector shaft shaft -1- in one position (gap in splines -arrow-).

– Secure gearbox gearbox selector selector lever -2-. -2-. Tightening torque ⇒ Item 18 (page 32)

– Secure push push rod -1- ⇒ Item 27 (page 33) . 33) . – Secure connecting connecting rod -3- ⇒ page 32 . 32 .


– Plug in electrical connector -2- at gear detector switch -F208- .

– Detach tensioning tensioning strap -T10038-T10038- .

– Raise gearbox gearbox further and and tighten bolts -arrows-arrows- for tunnel tunnel cross member ⇒ page 58 . 58 . – Detach engine and gearbox gearbox jack -V.A.G 1383 A- with gearbox support -T40173- from gearbox.

52



– Remove body body brace.

– Install top starter starter bolt -2- with with spacer sleeve sleeve between starter and gearbox -arrow-.

– Tighten remaining remaining engine/gea engine/gearbox rbox securing securing bolts -1 … 6-. Tightening torques ⇒ page 57

– Attach connector connector to gearbox gearbox neutral neutral position sender sender -G701-G701-1-.



53


– Secure universal universal joint to steering steering box box ⇒ Rep. gr. 48 .

– Secure drive shafts (left (left and right) to flange flange shafts shafts on gearbox ⇒ Rep. gr. 40 .


– Install heat shield shield for drive shaft ⇒ page 56 . 56 .

– Remove transportation transportation lock -T40170-T40170- and assembly assembly aid T40169- . – Engage 6th 6th gear by pulling pulling out selector selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.

54



The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant. – Turn both front wheels together in one direction until the clutch module has turned through one complete revolution (360°). •

The inspe inspection ction hole hole -arro -arroww- should should be be visible visible again again in the re‐ re‐ cess on the gearbox housing.

Secure clutch module to drive plate as follows: •

Use new bolts.

•

Tigh Tighte teni ning ng torq torque ue ⇒ Item 3 (page 24)

•

Tighten Tighten bolts bolts using using ring ring span spanner ner insert, insert, 16 16 mm -V.A.G -V.A.G 1332/14- .

– Install first bolt -arrow-arrow- and and tighten hand-tight hand-tight (2 Nm). – Turn both front wheels so that clutch module turns 120° further in direction of engine rotation and install second sec ond bolt hand-tight (2 Nm). – Turn clutch module 120° further in direction direction of engine engine rotation. – Then screw in and tighten tighten third bolt. Tightening Tightening torque torque ⇒ Item 3 (page 24) – Now tighten the the remaining remaining two bolts. Tightening Tightening torque torque ⇒ Item 3 (page 24) The remaining installation steps are carried out in reverse se‐ quence; note the following: – Install particulate particulate filter filter and front exhaust exhaust pipe ⇒ Rep. gr. 26 . – Install air cleaner cleaner housing housing ⇒ Rep. gr. 23 . – Attach hydraulic hydraulic lines for power power steering steering ⇒ Rep. gr. 48 . – Check gear oil level in gearbox gearbox ⇒ page 61 . 61 .



55


– Install subframe subframe cross brace brace ⇒ Rep. gr. 40 . – Install noise insulation insulation ⇒ Rep. gr. 66 . – Install body brace brace ⇒ Rep. gr. 40 . – Observe correct correct procedure procedure after connecting connecting battery battery ⇒ Rep. gr. 27 .

♦ Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. ♦ Additional lubricant lubricant such as engine or or gear oil may may be used, used, but do not use graphite lubricant. ♦ Do not use parts which have been degreased. ♦ Tolerance for tightening torques is ± 15 %.

Bolts and nuts

M6 9 M7 15 M8 20 M10 40 M12

65

Except for the following:

– Tighten bolts bolts -arrows- for for drive shaft shaft heat shield to 23 Nm.


56



1 1)

M10x50

2 3)

M12x100

2) 4)

65 30 + 90°

3 5), 6

M12x75 4)

4, 5 5)

M12x120

7…9

M10x75

4)

15 + 90°

10

M12x50

4)

30 + 90°

A

4)

30 + 90° 30 + 90°

Dowel sleeves sleeves for centralising centralising

•

1) Also

•

2) Steel

•

3) Also

•

4) Check

•

5) Also

secures starter. bolt - do not renew.

secures starter, with additional spacer sleeve be‐ tween starter and gearbox. whether aluminium bolts can be reused ⇒ page 57 and 57 and renew if necessary. secures bracket for electrical wiring.

♦ Aluminiu Aluminium m bolts -2 -2 … 10- can can be used used twice only. only. After After they they have been used once, an „X“ -arrow- must therefore be chi‐ selled onto the bolts. ♦ To prevent prevent dama damage ge to the bolts bolts,, they must must not be clampe clamped d in a vice when marking them. Clamp a 14 mm socket with 1/2” drive in the vice instead, and insert the bolt into the socket, as shown in illustration. ♦ Bolts Bolts marked marked with with an „X“ „X“ must must not be be used used again. again. ♦ The steel steel bolt bolt -1- can can be re-used re-used any any number number of times. times.



57


❑ 20 Nm ❑ 70 Nm ❑ 40 Nm ❑ 20 Nm ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 60 ❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 60 ❑ For For gea gearb rbox ox moun mounti ting ng ❑ 20 Nm + 90° ❑ Renew


❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ page 58

♦ Engine Engine and and gearb gearbox ox jack jack -V.A.G -V.A.G 1383 1383 AA-

58



♦ Gear Gearbo box x suppo support rt -T10 -T1033 3377-


– Apply lifting column column of engine engine and gearbox gearbox jack -V.A.G -V.A.G 1383 A- to gearbox gearbox from below below (with gearbox gearbox support support -T10337-T10337- at‐ tached). – Slightly lift gearbox gearbox with engine engine and gearbox jack -V.A.G 1383 A- .

– Remove bolts bolts -arrows- for for tunnel cross cross member.


5. Exploded view - tunnel cross member, gearbox mounting and gearbox support

59


– Unscrew nuts -arrows-arrows- and and remove tunnel tunnel cross member. member.

Installation is carried out in reverse sequence; note the following: •

Tigh Tighte teni ning ng torq torque ues s ⇒ page 58

– Install rear noise noise insulation insulation ⇒ Rep. gr. 66 .

– Remove tunnel tunnel cross member member ⇒ page 58 . 58 . – Remove bolts -arrows- and detach gearbox support from gear‐ box together with gearbox mounting.

Installation is carried out in reverse sequence; note the following: • – Secure gearbox gearbox support support to gearbox gearbox together together with gearbox gearbox mounting -arrows-. Tightening torque ⇒ Item 3 (page 58) – Install tunnel cross member member ⇒ page 58 . 58 .

– Remove gearbox gearbox support support together together with gearbox gearbox mounting ⇒ page 60 . 60 . – Remove bolts bolts -1- and detach detach stop -2-2- (bottom) for for gearbox gearbox mounting. – Remove nut nut -4- and detach detach gearbox gearbox mounting mounting -5- from gear‐ gear‐ box support -3-.

•

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Tigh Tighte teni ning ng torq torque ues s ⇒ page 58 permitted perm itted unless authorised auth orised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit gearbox gearbox support -3- onto gearbox mounting -5- and tighten nut -4- hand-tight. – Secure stop (bottom) -2-2- with bolts -1-. -1-. – Tighten nut nut -4-. – Install gearbox gearbox support support with gearbox gearbox mounting ⇒ page 60 . 60 .

60



The vehicle must be horizontal when checking gear oil level. – Remove noise noise insulation (rear) -2-2- ⇒ Rep. gr. 66 .

– To check gear gear oil level, unscrew unscrew oil filler plug -arrow-. -arrow-. •

Specifica Specification tion:: Oil level level is corre correct ct when when gearbox gearbox oil is up up to low‐ low‐ er edge of filler hole.

– Top up with gear oil if necessary. necessary. Specification Specification ⇒ page 2 . 2 . – Screw in oil filler filler plug.

Oil filler plug

45


6. Checking oil level in manual gearbox

61


♦ Engine Engine and and gearb gearbox ox jack jack -V.A.G -V.A.G 1383 1383 AA-

♦ Gear Gearbox box sup suppo port rt -T10 -T1033 3377-


♦ Relea Release se tool tool -T40 -T4013 1388-

62




The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10 ° - otherwise it can be damaged. – Disconnect exhaust exhaust system at clamp clamp -arrows-. -arrows-. – Using suitable suitable wire, tie up front front exhaust pipe pipe to one side side of rear section of exhaust system (at clamp). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

– Apply lifting column column of engine engine and gearbox gearbox jack -V.A.G -V.A.G 1383 A- to gearbox gearbox from below below (with gearbox gearbox support support -T10337-T10337- at‐ tached). – Slightly lift gearbox gearbox with engine engine and gearbox jack -V.A.G 1383 A- .

– Remove bolts bolts -arrows- for for tunnel cross cross member.

7. Removing and installing gear detector switch F208 with gearbox installed

63


– Lower gearbox gearbox by dimension dimension -a- using engine engine and gearbox gearbox jack -V.A.G 1383 1383 A- . •

Dimen Dimensio sion n -a-a- = 60 60 mm mm (ma (maxim ximum um))

– Use release tool -T40138-T40138- to unplug unplug electrical connector connector -arrow- and move clear. – Unscrew gear gear detector detector switch -F208-F208- from selector shaft shaft cov‐ er.

– Screw gear detector switch -F208-F208- into selector shaft shaft cover. Tightening torque ⇒ page 64 – Plug in connector connector at gear gear detector switch switch -F208- .

-Item 1- and -item 3- can be disregarded.

– Secure tunnel tunnel cross member member -arrows-arrows- ⇒ Item 2 (page 58) . 58) . – Assemble exhaust exhaust system and and align so it is free free of stress ⇒ Rep. gr. 26 . – Install rear noise noise insulation insulation ⇒ Rep. gr. 66 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted permit ted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

Gear detector switch -F208-

64


20


•

Only Only in in vehic vehicles les with with star start/s t/stop top system system



– Engage 4th 4th gear by shifting shifting gearbox gearbox selector lever lever -2- for‐ wards in direction of -arrow-.


– Unplug electrical electrical connector connector from gearbox gearbox neutral neutral position sender -G701- -1-.

8. Removing and installing gearbox neutral position sender G701

65


– Remove bolt bolt -arrow- and and pull out gearbox gearbox neutral neutral position sender -G701- -A-.

Sealing cap -B- remains fitted.

– Insert gearbox neutral position sender -G701- -A- with new new Oring in sealing cap -B- for selector shaft. – Tighten new new bolt -arrow-arrow- to specified torque ⇒ page 66 . 66 . – Attach connector connector to gearbox gearbox neutral neutral position sender sender -G701-G701-1-. – Install rear noise noise insulation insulation ⇒ Rep. gr. 66 .

Gearbox neutral position sender -G701•

10 + 45°

Renew bolt


66



♦ Extrac Extractor tor too tooll -T201 -T20143 43/1/1-

♦ Shock Shock abso absorb rber er set set -T100 -T1000101-


♦ Pull Puller er -T40 -T4016 1600-

♦ Seali Sealing ng gre grease ase -G 052 052 128 128 A1A1-

9. Removing and installing oil seal for selector shaft with gearbox installed

67


– Engage 1st 1st gear. – Remove noise noise insulation (rear) -2-2- ⇒ Rep. gr. 66 .




– Apply puller -T40160-T40160- and pull off off gearbox selector selector lever. lever.

– Prise out oil seal seal with extractor extractor tool -T20143/1-T20143/1- . •

Check Check select selector or shaft shaft for dama damage. ge.

68



– Lightly oil outer outer circumference circumference of oil seal. seal. – Pack space space between between sealing lip and and dust dust lip half-full with seal‐ seal‐ ing grease -G 052 128 A1- . – Drive in oil seal seal with -T10001/1-T10001/1- . •

Installati Installation on depth: depth: 2 mm below below surfac surface e of housing housing

– Install gearbox gearbox selector lever lever as follows: •

Gearbo Gearbox x selector selector lever lever -2-2- can only be be fitted fitted onto onto selector selector shaft shaft -1- in one position (gap in splines -arrow-).

– Secure gearbox gearbox selector selector lever. Tightening Tightening torque torque ⇒ Item 18 (page 32) – Install rear noise insulation insulation ⇒ Rep. gr. 66 .


9. Removing and installing oil seal for selector shaft with gearbox installed

69


For a detailed description please refer to the Workshop Manual ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 34 .


70





1. Dismantling and assembling input shaft and output shaft

71


♦ Renewing Renewing oil oil seal for for flange flange shaft shaft (right-si (right-side) de) ⇒ page 72 . 72 . ♦ The flange flange shaft shaft oil seal seal (left-side (left-side)) can only only be renewed renewed with the gearbox removed from the vehicle ⇒ Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr. 39 .

♦ Drif Driftt -VW -VW 295295-

♦ Multi Multi-p -purp urpose ose too tooll -VW 771 771--


♦ Eye-h Eye-hea ead d bolt bolt -33 -3368 68--

72

Rep. gr.39 - Final drive - front differential


♦ Thrus Thrustt piec piece e -T40 -T40163 163--

♦ Used oil oil collectio collection n and extrac extraction tion unit unit -V.A.G -V.A.G 17821782-


♦ Lever ♦ Seali Sealing ng gre grease ase -G 052 052 128 128 A1A1-

•

Gear Gearbo box x is inst instal alle led. d.

•

Refer Refer to to gene genera rall repai repairr instr instruct uction ions s ⇒ page 4 . 4 .

– Remove front front right wheel. wheel. – Remove noise noise insulation (rear) -2-2- ⇒ Rep. gr. 66 .

1. Renewing oil seals for flange shafts

73


– If fitted, remove noise insulation -1- from wheel housing (rightside).

– Remove bolts bolts -arrows- and and detach heat heat shield for drive shaft (right-side).

– Detach drive shaft (right-side) (right-side) from gearbox gearbox and and place to one one side ⇒ Rep. gr. 40 .

Place drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS 6208- under the gearbox. – Screw eye-head eye-head bolt bolt -3368-3368- into threaded threaded hole in flange shaft shaft (right-side). – Attach multi-purpose multi-purpose tool tool -VW 771- with -VW 771/13771/13- to eyehead bolt and knock out flange shaft.


74



– Lever out flange flange shaft oil oil seal.


Installation is carried out in reverse sequence; note the following: – Always renew renew circlip for flange flange shaft -A-. – Clamp flange flange shaft in vice, using jaw jaw protectors. protectors. Use new cir‐ cir‐ clip -A- to press old circlip out of groove in flange shaft.

– Lightly oil outer outer circumference circumference of new oil seal. – Drive in new flange flange shaft oil oil seal (right-side) (right-side) as far as as stop; keep seal straight when installing. – Pack space space between between sealing lip and and dust dust lip half-full with seal‐ seal‐ ing grease -G 052 128 A1- . – Knock flange shaft in with drift drift -VW 295- .

– Bolt drive shaft shaft to flange shaft shaft ⇒ Rep. gr. 40 . – Fit drive shaft shaft heat shield.

1. Renewing oil seals for flange shafts

75


– If fitted, install noise noise insulation -1-1- in wheel wheel housing (right(rightside). – Fill up oil in gearbox gearbox and and check oil level level ⇒ page 61 . 61 . – Install noise insulation insulation ⇒ Rep. gr. 66 .

Heat shields for drive shafts to gearbox

23


76





2. Front differential

77

Manual-6Vel-0B1.pdf

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