Audi A4 with 2001- 2005 of release.
1. Operation and car maintenance service
2. The engine
3. Transmission
3.1. Coupling
3.2. A mechanical transmission
3.2.1. A six-speed transmission 0А3 (a full drive)
3.2.2. A six-speed transmission 01E / 0A1 (a forward drive)
3.2.3. The general recommendations about preventive maintenance and repair of mechanical transmissions
3.2.4. Level check трансмиссионного oils in a mechanical transmission
3.2.5. Removal and installation of a knob from a cover
3.2.6. Removal and installation of a drive of a gear change
3.2.7. Adjustment of a drive of a gear change
3.2.8. Removal and installation of a pillow of a transmission
3.2.9. Removal and installation of lock plugs of a shaft of a gear change at the established transmission
3.2.10. Removal of switches of lanterns of a backing
3.3. An automatic transmission
3.4. The privodnoj mechanism
3.5. Tables
4. A running gear
5. The steering mechanism
6. Brake system
7. An onboard electric equipment
8. A body
9. Electric equipment schemes
 







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3.2.3. The general recommendations about preventive maintenance and repair of mechanical transmissions

Transmission
Bolts and other details should be selected according to an alphabetic code of a transmission.
At transmission replacement check up oil level in a box and if necessary add.
Carefully clear junctions and a reducer surface.
At transmission installation watch correct position of aligning plugs.
Shnurovye consolidations, linings, sealing cuffs.
Ring шнуровые consolidations, linings and sealing cuffs are subject to replacement by the new.
After removal of consolidations examine airfields on the case and on a shaft on presence of damages at dismantle.
Carefully clear dividing surfaces of the case before assemblage.
For radial consolidation of a shaft before installation it is necessary to grease sealing rings slightly on external diameter and to fill in them space between edges to half герметизирующей plastic greasing.
The open party of a sealing cuff establish to a condensed liquid.
New sealing cuff compress and exactly establish to the place of the old. (Use the adaptation for deep запрессовки).
Before installation slightly смажте sealing rings to prevent раздавливание rings at installation.
After replacement of consolidations and sealing rings check up oil level in a transmission.

Hermetic
Carefully clear dividing surfaces of the case before hermetic drawing.
Put hermetic uniform and not too thick layer.
Hermetic should not get to ventilating apertures.

Lock elements
Do not draw lock rings.
The damaged or drawn lock rings are subject to replacement.
Lock rings should adjoin in the groove basis.

Fig. 3.45. The scheme of installation of lock rings


Tightening plugs replace. An arrangement: шлиц And it is located along loading distribution (fig. 3.45).

THE NOTE
The tightening plug / tightening a pin of fastening of a switching plug / of a rod of a plug of switching of 5/6 transfers act in film and established only by means of the press adaptation.

Bolts, nuts
Nut bolts / unscrew in an order, the return to a twisting.
Consistently establish all bolts and nuts for fastening of covers and the case without screwing up and then crosswisely tighten.
Do not warp especially easily damaged details, for example a coupling plate, turn on and tighten them cross-wise, gradually.
The inhaling moments are given for not greased bolts and nuts.
Самоконтрящиеся bolts and nuts are subject to replacement.
Carving of bolts / of the screws greased at an inhaling with a carving clamp, clear a wire brush. Then insert screws with a clamp.
Carving apertures in which self-stopped screws or screws with a clamp have been twisted, it is necessary to clear (for example, by means of a tap). Otherwise at the following dismantling their carving can be broken.

Bearings
Needle bearings насаживайте the marked party (thicker part) to the tool for запрессовки.
The needle bearing of a switched gear wheel of 1-6 transfers at removal note, that at assemblage to establish them in the same position.
Смажте the needle bearing of a power shaft of a transmission behind in a flywheel.
Establish all bearings in the case of a transmission with трансмиссионным oil.
Internal rings of conic roller bearings before installation heat up approximately to 100 C, at installation запрессовывайте without axial люфтов against the stop.
Do not mix external and internal rings of identical bearings on the size.
The conic roller bearings located on one shaft, always replace in gathering and use products of one manufacturer.
Conic roller bearings of a power shaft and differential in a transmission work with small losses on a friction. New conic roller bearings for measurement of the moment of forces of a friction in addition do not grease. For this purpose at factory bearings process special oil.

Adjusting washers
Supervise the size of adjusting washers in several points by means of a micrometer. Various admissions give the chance to measure a demanded thickness of washers precisely.
Check up on presence of agnails or damages.
Use only the faultless and intact adjusting washers.

Gear wheels, synchronizers, internal rings switched by a gear wheel
Gear wheels and synchronizers before installation heat up approximately to 100 C, at installation запрессовывайте without axial люфтов against the stop.
For installation of internal rings switched by a gear wheel heat up them approximately to 100 C.
The temperature can be checked up by means of the thermometer.
Watch assembly position.

Gear wheels-carriages
After installation switched by a gear wheel check up their free a course, and also presence axial люфтов.
Preset value of a switched gear wheel of 1st speed: 0,15–0,50 mm.
Preset value of a switched gear wheel of 2-6 speeds: 0,15–0,35 mm.

Blocking rings of the synchronizer
At a reuse of a ring of the synchronizer identify on a gear wheel of the same transfer and do not mix.
Check up blocking rings on deterioration presence; if necessary replace.
Establish, having greased трансмиссионным with oil.

Блокираторы the synchronizer with молибденовым a covering
The surface of a friction efficient блокиратора the synchronizer with молибденовым a covering looks, as graphite and has slightly porous surface (блокиратор it is necessary to clean). The friction surface should be degreased

Fig. 3.46. Затертости on a friction surface блокиратора the synchronizer


If on a friction surface strongly brilliant places were formed And, or even the brass basis seemed, блокиратор is subject to replacement (fig. 3.46).

Deterioration of plugs of inclusion switched by a gear wheel /

Fig. 3.47. Deterioration блокиратора the synchronizer or a switched gear wheel: A – worn out скос teeths блокиратора the synchronizer or a gear wheel


Deterioration блокиратора the synchronizer or a switched gear wheel it is shown in drawing 3.47.

Fig. 3.48. Intact блокиратор the synchronizer: B – Normal скос teeths блокиратора the synchronizer or a gear wheel


Intact блокиратор the synchronizer / a gear wheel it is shown in drawing 3.48.

Fig. 3.49. Deterioration of the plug of inclusion: C – worn out скос teeths of the plug of inclusion


Deterioration of the plug of inclusion is shown in drawing 3.49.

Fig. 3.50. The intact plug of inclusion: D – Normal скос teeths of the plug of inclusion


The intact plug of inclusion is shown in drawing 3.50.
Блокираторы сихронизатора with карбоновым a covering vary together with the inclusion plug. Depending on a deterioration picture replace also switched gear wheels.

Coupling drive
At transmission dismantle dismantle the working cylinder of coupling, thus do not open system.
At dismantle of the working cylinder of coupling with the connected tubes of a hydrodrive – do not squeeze out a coupling pedal. Otherwise the piston will be superseded from the working cylinder of coupling. The working cylinder of coupling will be destroyed.
If the pedal of coupling after connection process does not come back in initial working position (a coupling pedal in rest position), it is necessary to pump over a coupling drive.
Do not warp press a coupling disk; turn off and twist in some stages with a small difference in the inhaling moment.
On all cars disk SAC on which in case of replacement of one only a coupling disk it is necessary to establish into place an adjusting ring is established press.
For liquidation of a smell of burnt coupling it is necessary to clear carefully картер couplings, a flywheel and the engine on the transmission party.


3.2.2. A six-speed transmission 01E / 0A1 (a forward drive)

3.2.4. Level check трансмиссионного oils in a mechanical transmission