2000 AUDI A6 01E Transmission Bearing House And Torsen Differential Workshop Manual

34-61


Note:
The internal extractor 3275 grips the circumferential groove of the inner
race (arrow) during the pulling operation. - Pull 2nd inner race for ball bearing for input shaft from input shaft.
A - Washer
- Take off end cover together with end cover/bearing plate gasket.
- Pull dowel sleeves out of bearing plate.

- Pull off 5th speed sliding gear with spring together with 1st inner race -
A- for ball bearing for input shaft.
B - Two arm puller, e.g. Kukko 20/10
- Take off 5th gear synchro-ring.
- Take off circlip for 5th speed gear.
Pa
ge 9 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
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pair&id=AUDI.B5.TM03.34.5

34-62


Note:
Use only hex bolt of tensioning sleeve 3116, length 50 mm. - Pull off 5th speed gear, to do this, block hollow shaft by engaging 2
gears Page 34
-59
.
C - Two arm puller, e.g. Kukko 20/10 with 200 mm long puller arms
- Remove shim -B- for 5th speed gear, note thickness and re-determine
if necessary Page 34
-78
.
- Take off spacer sleeve -A-.

Note:
Do not drive out roll pin, otherwise selector rod bearing will be damaged. - Press out roll pin -A- for selector fork for 5th and 6th gear.
- Pull selector rod on follower together with selector fork for 5th and 6th
gear and locking collar as far as possible away from bearing plate (until
stop is felt).
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ge 10 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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play?action=Goto&t
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pair&id=AUDI.B5.TM03.34.5

34-63


- Mark installation position (arrow -3-) of locking collar for 5th and 6th
gear (arrow -1-) and synchro-hub -A- (paired).

- Pull follower together with selector fork and locking collar off selector
rod.
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ge 11 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-64


- Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub
for 5th and 6th speed gears and inner race for 5th speed sliding gear.
A - Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks

- Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Mark fitting locations of aluminium and steel bolts. (Bolts must not be
interchanged when installing.)
- Drive out dowel sleeves on bearing plate and remove bearing plate
from transmission housing.
- Secure drive pinion relative to hollow shaft e.g. hose tie, to prevent it
falling out.
Pa
ge 12 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.TM03.34.5

34-65

- Separate bearing plate with input shaft, with
drive pinion and hollow shaft and with inner
selector mechanism from transmission housing.

- Remove circlip from selector rod for 1st and 2nd gear and take off
follower -A-.
- Pull out selector rod -B- for 5th and 6th gear.
- Remove follower -C- for reverse gear.

- Pull thrust washer (arrow -A-) for needle bearing for 6th gear off shaft.
- Use right-angled circlip pliers to remove circlip (arrow -B-) for inner
race for cylinder roller bearing.
- Take out inner race (arrow -C-) for cylinder roller bearing (not a press
fit).
Pa
ge 13 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-66


- Take input shaft -A- with selector rod and selector fork for 3rd and 4th
gear out at an angle from bearing plate.

Removing and installing reverse gear Page 34
-114
. - Unscrew hex bolt -D-, take off spring clasp -B- and retaining plate -A-,
pull out shaft -C- for reverse idler gear.
- Take out spring, synchro-ring and reverse idler gear.
- Take off relay lever for reverse gear.
Pa
ge 14 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
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pair&id=AUDI.B5.TM03.34.5

34-67

Note:

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

- Remove drive pinion circlip.

Note:
Carefully protect bearings from dirt, clean if necessary. - Pull drive pinion out of hollow shaft -D-, when doing this catch tapered
rollers -A- (Qty. 23).
- Take off corrugated spring -B- and needle ring -C-.
Pa
ge 15 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
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play?action=Goto&t
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pair&id=AUDI.B5.TM03.34.5

34-68


- Check bearing to ensure it is complete:
1 - Flange ring (tapered contact surface to tapered rollers)
2 - Tapered rollers (Qty. 23) with larger diameter facing towards drive
pinion head
3 - Support ring (tapered contact surface to tapered rollers)
4 - Corrugated spring
5 - Circlip for tapered roller bearing for drive pinion

Note:
Because of the type of fit, it may be possible to press gear off easily. - Press off 6th speed gear.
- Take hollow shaft or drive pinion and hollow shaft with selector rod and
selector fork for 1st and 2nd gear out of bearing plate.
Pa
ge 16 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5