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

34-69

Installing

- Fit hollow shaft with selector fork and selector
rod for 1st and 2nd gear (without follower) into
bearing plate.

-
Heat 6th gear to approx. 120 C and fit on. Installation position: shoulder towards tapered roller bearing
- Press onto stop; ensure there is no play.
- Grease drive pinion/hollow shaft tapered roller bearing with multi-
purpose grease before inserting.
Allocation Page 34
-68


A - Flange ring, tapered rollers (Qty. 23), and support ring
B - Corrugated spring
C - Needle ring
D - Hollow shaft
- Oil needle bearing well.
Pa
ge 17 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
yp
e=re
pair&id=AUDI.B5.TM03.34.5

- Insert drive pinion into hollow shaft and secure with hose clip to prevent
it slipping out.
Pa
ge 18 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

34-70


- Fit relay lever -A- for reverse gear onto bolt for relay lever. Watch
position of pin when doing this (limits relay lever travel to synchro-ring).
- Insert sliding gear -B- and engage relay lever with groove on sliding
gear.
- Insert synchro-ring -C-.
Installation position: position flat on circumference of synchro-ring
towards input shaft (not as yet fitted) (arrow -1-)
- Insert spring.
Installation position: hook single angled end into recess on synchro-
ring (arrow -2-). Turn double angled end anti-clockwise and hook into
opening in bearing plate (arrow -3-)
Pa
ge 19 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

34-71


- Insert shaft -C-.
- Fit retaining plate -A-.

Installation position: chamfers of holes for locking pins of the
synchro-ring face bearing plate
- Insert spring clasp -B- into locking pins of the synchro-ring.
- Replace self-locking nut -D- and tighten to 25 Nm.

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

Selector fork installation position: rib towards follower Page 34
-
52

Pa
ge 20 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

34-72


- Slide inner race (arrow -C-) for cylinder roller bearing onto main shaft at
flange for end cover (clearance fit).
- Fit circlip (arrow -B-) using right-angled circlip pliers.

- Engage recess in follower for reverse gear with the free end of relay
lever (arrow -A-).
- Slide selector rod for 5th and 6th through follower for reverse gear in
direction of (arrow -B-).
Pa
ge 21 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

34-73


- Slide follower -A- for 1st and 2nd gear onto selector rod and secure
with circlips.
- Oil all bearings of input shaft and drive pinion/hollow shaft in
transmission housing and bearing flange as well as selector rods with
gear oil.

Note:
When inserting the complete bearing plate, ensure that the selector rods
align with their mounting points. - Pry used seal for input shaft carefully out of transmission housing with
VW 681.
- Coat sealing surfaces between bearing plate and transmission housing
with sealing paste AMV 188 000 02 or AMV 188 001 02 sealing paste.
- Insert complete bearing plate into transmission housing.
Pa
ge 22 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

34-74

- Drive in 2 dowel sleeves for bearing
flange/transmission housing.

- Tighten 12 bolts using diagonal sequence to 25
Nm.

Note: - Screw in locking bolts for selector rods.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
Aluminium and steel bolts must not be interchanged when installing.Tightening torques: for aluminium locking bolts = 50 Nm, and for steel
locking bolts = 70 Nm
Pa
ge 23 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

34-75


- Fit thrust washer (arrow -A-) for needle bearing for 6th speed gear.
Installation position: shoulder towards circlip (arrow -B-), smooth
contact surface to shaft end
- Oil needle bearing for 6th speed sliding gear with gear oil and fit.
- Slide on 6th speed sliding gear with spring and synchro-ring.
Synchro-ring installation position: the lugs of the synchro-ring engage
into the recesses below in the sliding gear

- Support input shaft with support bridge 30-211 A.
Pa
ge 24 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