1996 AUDI A4 transmission

00-10


General repair instructions
The maximum possible care, cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also 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
Manual, are summarized here. They apply to this
Repair Manual.

Special tools and equipment
For a complete list of special tools and
equipment used in this repair manual "Special
tools catalog."
Transmission

Using parts catalog microfiche, match bolts and
other components according to transmission
codes Page 00
-3 .

After replacing the manual transmission , check
oil level and top-up if necessary Page 34
-36
.

Capacities and specifications Page 00
-3 .

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Thoroughly clean all connections and the
surrounding area before disconnecting.
When installing transmission, make sure
centering sleeves for aligning engine and
transmission are correctly seated.
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Lightly lubricate O-rings before installing. This prevents the rings from
being pinched while being inserted. Check transmission oil level after replacing gaskets and seals Page 34
-36
.
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00-13

Bearings

Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing the
drift.
Mark needle bearings of drive gears for first
through fifth sliding gears when removing to
ensure the same installed position when
installing.
Grease needle bearing for input shaft in
flywheel.
Lubricate all bearings in transmission with
transmission fluid before installing.
Heat tapered roller bearing inner races to
approx. 100 C (212 F) before installing. Press
in to stop so that there is no axial play.

Do not interchange inner and outer bearing
races with those from other bearings of the
same size.
Always replace tapered roller bearings on one
shaft together and use new bearings from the
same manufacturer.
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The tapered roller bearings for the output shaft
and the differential in the manual transmission
are low-friction bearings. Do not additionally oil
new tapered roller bearings when measuring
friction torque. The bearings are pre-treated at
the factory with a special type of oil for this
purpose.
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00-14

Shims

Use a micrometer to measure the shims at
several points. Different tolerances make it
possible to obtain the exact shim thickness
required.
Check for burrs and signs of damage.

Sliding Gears
After assembling, check axial play of 1st to 5th
sliding gears (0.15-0.35 mm) and check for free
movement.

Synchronizer rings
Do not interchange. When re-using, install
synchronizer rings with the same gear with
which they were matched.
Check for signs of wear; replace if necessary.
Lubricate with transmission fluid before
installing.

Gears, synchro-hubs, inner races for sliding
gears
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00-15

Clutch mechanism

When removing transmission, remove clutch
slave cylinder without disconnecting lines.
Do not depress the clutch pedal after removing
the slave cylinder if the hydraulic line is still
connected. Otherwise the piston will be pressed
out of the slave cylinder.
Do not cant clutch pressure plate; loosen and
tighten in a diagonal sequence and in stages.
If the clutch has burnt out, thoroughly clean the
bellhousing, flywheel and parts of the engine
facing the transmission in order to reduce the
smell of burnt linings.
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pair instructions
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.00.4