00-11
Repair instructions
The maximum possible care and cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also, naturally apply
when carrying out vehicle repairs.
A number of generally applicable instructions for
individual repair operations, which are otherwise
mentioned at various points in the Repair
Manual, are summarized here. They apply to this
Repair Manual.
Special tools
For a complete list of special tools used in this
Repair Manual
Special Tools Catalog
Transmission
When installing a replacement transmission or
rear final drive, check oil level and top-up if
necessary Page 34
-39
and Page 39
-80
.
Vehicles with 2.7 ltr 195 kW engine:
replacement transmissions contain an
additional 0.3 ltr of oil for the lines of the
Pa
ge 1 of 12 Re
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.TM03.00.5
00-17
Synchronizer rings
Do not interchange synchronizer rings. When
reusing always fit to the same gear.
Check for wear, replace if necessary.
Lubricate with gear oil before installing.
Clutch mechanism
When removing transmission, remove clutch
slave cylinder without disconnecting lines.
If the slave cylinder is removed with the
hydraulic line attached, do not depress clutch
pedal. Otherwise the piston will be pressed out
of the slave cylinder.
Ensure that the pressure plate is kept straight:
loosen and tighten bolts in a diagonal sequence
and in several gradual stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the clutch bellhousing, the
flywheel and the parts of the engine facing the
transmission.
Pa
ge 11 of 12 Re
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.TM03.00.5
