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

34-76


Installation position of synchro-hub for 5th and 6th gear:
Side with projecting face (arrow -1-) faces shaft end The oil drilling of the input shaft (arrow -2-) and the oil groove of the
synchro-hub (arrow -3-) are in line

-
Heat synchro-hub for 5th and 6th gear to approx. 100 C, fit and drive
on; ensure there is no play. - Check 6th speed sliding gear for axial play.
Pa
ge 25 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
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e=re
pair&id=AUDI.B5.TM03.34.5

34-77


Note: - Line up markings (arrow -3-) on paired synchro-hub -A- and locking
collar for 5th and 6th gear (arrow -1-).
- Fit locking collar (arrow -1-) with selector fork (arrow -2-) onto synchro-
hub -A- as well as follower for 5th and 6th gear -B- onto selector rod -
C- at the same time.
Selector fork rib (arrow -2-) must face towards shaft end. When sliding follower onto selector rod for 5th and 6th gear remember
holes for roll pin.

Note:
Do not drive in roll pin, otherwise selector rod mounting will be damaged. - Press in roll pin -A- flush.
Pa
ge 26 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

34-78
Re-determining shim for 5th speed gear:

Parts catalog
The following shims are available: - Fit spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
- When fitting circlip, push in direction of arrow onto stop.
- Measure distance between sleeve and fitted circlip with depth gauge -
B-.
- Determine shim from table.Measured range (mm)
Shim thickness (mm)
31.01-31.11 1.05
31.11-31.21 1.15
31.21-31.31 1.25
31.31-31.41 1.35
Pa
ge 27 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

34-79


- Fit shim selected (arrow) onto hollow shaft.

-
Heat 5th speed gear to approx. 120 C, fit and drive onto stop free of
play.
Installation position: shoulder toward spacer sleeve
Pa
ge 28 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

34-80


Re-determining circlip for 5th speed gear:
Parts catalog
The following circlips are available: - Determine thickest circlip that can still just be fitted.
- Determine circlip from table.Circlip thickness (mm)
2.32 2.40 2.48
2.34 2.42 2.50
2.36 2.44
2.38 2.46 - Fit circlip.
Pa
ge 29 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

34-81


- Drive on inner race for 5th speed sliding gear free of axial play.
- Oil needle bearing with gear oil and fit.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th speed sliding gear with spring.

-
Heat 1st inner race for ball bearing for input shaft to approx. 100 C, fit
onto input shaft and drive onto stop; ensure there is no play. - Check 5th speed sliding gear for axial clearance.
Permissible axial clearance: 0.15-0.35 mm
- Insert dowel sleeves into bearing plate.
- Fit new gasket for end cover.
Pa
ge 30 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

34-82


Note:
Do not tighten bolts. - Fit end cover and insert securing bolts (arrows -B-).
- Clean two magnets (arrows -A-) and insert.
- Fit support plate and tighten hand tight.

Installation position: Lugs towards magnets
- Tighten bolts for end cover using diagonal sequence.

- Oil 2nd inner race and with ball contact surface facing towards input
shaft ball bearing, drive onto input shaft through hole in end cover.
- Remove support bridge 30-211 A.
Pa
ge 31 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

34-83


- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear), do
this by moving two selector plates (arrows).
- Tighten multi-point socket head bolt to 150 Nm.

- Unclip cover -3- for oil collector from oil collector -1- at longer end with
a screwdriver and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
Pa
ge 32 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