Service

Workshop Manual
Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive
Edition 01.2012

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt D3E804905D7

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification of magnesium gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Calculating ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 by copyright.
Protected Contact corrosion!
Copying . . . . . . purposes,
for private or commercial . . . . . .in.part
. . or. .in.whole,
. . . .is .not. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 unlessGeneral
permitted repair
authorised by AUDI AG.instructions
AUDI AG does not . .guarantee
. . . . . or
. .accept
. . . .any
. .liability
................................... 12
with respect to the correctness of information in this document. Copyright by AUDI AG.

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Servicing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Exploded view - pedal cluster (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2 Removing and installing clutch pedal and over-centre spring . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Exploded view - pedal cluster (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Exploded view - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 25
1.6 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.8 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Exploded view - clutch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Servicing gear selector mechanism for vehicles up to 05.99 . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Exploded view - standard-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Removing and installing standard-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Adjusting standard-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Exploded view - servicing short-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5 Removing and installing short-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.6 Adjusting short-travel selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number
8D-X-260 001 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Servicing gear lever and push rod (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Servicing selector rod and push rod (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Removing and installing gear lever with push rod (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Removing and installing selector mechanism from 05.99 onwards . . . . . . . . . . . . . . . . . . 60
2.6 Adjusting selector mechanism from 05.99 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7 Checking gear lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Contents i
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

5.2 Exploded view - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.3 Exploded view - removing and installing input shaft ball bearing and multi-function sender
........................................................................ 81
5.4 Exploded view - removing and installing input shaft, pinion shaft, selector rods and gearbox
cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.5 Assembly sequence - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . 85
6 Dismantling and assembling selector mechanism in gearbox . . . . . . . . . . . . . . . . . . . . . . 93
6.1 Checking and renewing locking unit for 5th gear and reverse gear . . . . . . . . . . . . . . . . . . 97

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Dismantling and assembling input shaft, renewing roller bearing/needle bearing for input
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.1 Exploded view - pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2 Dismantling and assembling pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.3 Reinforcements from 08.98 onwards (from gearbox manufacturing date 17 08 8 onwards) in
area of 4th gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3 Removing and installing reverse gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2 Removing and installing speedometer sender and drive wheel . . . . . . . . . . . . . . . . . . . . . . 134
2.1 Removing and installing speedometer sender G22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.2 Removing and installing speedometer drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.1 Removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.1 Adjustment and marking of final drive gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.2 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.3 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.4 Re-adjustment sequence for final drive gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.5 Adjusting pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.6 Re-determining shim „S4“ when renewing gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

ii Contents
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

00 – Technical data
1 Gearbox identification

Note

Manual gearboxes 012, 01W and 0A9 are identical. Designations

01W and 0A9 are used only during production and do not appear
as gearbox code.

The 5-speed manual gearbox 012/01W/0A9 is fitted in conjunc‐

tion with 4-cylinder engines and 6-cylinder injection engines in the
Audi A4 1995 >.
Allocation
⇒ „1.2 Code letters, allocation, transmission ratios, capacities“,
page 2 .
Location on gearbox
Code letters and date of manufacture -arrow 1-
Manual gearbox 012/01W/0A9 -arrow 2-

Manual gearbox 012/01W/0A9 -arrow 2-

Code letters and date of manufacture of gearbox -arrow 1-

Example: DHW 15 10 6
I I I I
I I I I
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Code letters Day Month Year -1996-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
of manufacture
with respect to the correctness of information in this document. Copyright by AUDI AG.

Additional data are manufacture-related.

Note

The code letters of the gearbox are also given on the vehicle data
stickers.

1. Gearbox identification 1
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1.1 Identification of magnesium gearboxes

The identification marking, e.g. „Mg Al 9 Zn 1“ can be found near
-arrow 1- and -arrow 2- on gearboxes with a magnesium housing.
The gearbox code letters also indicate whether a gearbox has a
magnesium housing
⇒ „1.2 Code letters, allocation, transmission ratios, capacities“,
page 2 .

1.2 Code letters, allocation, transmission ra‐

tios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Gear oil specification
♦ Correct type of clutch plate and pressure plate
Manual gearbox 5-speed 012/01W, front-wheel drive
Code letters AOE 1) APL CPC CPD
Manufactured from 11.94 12.95 11.94 11.94
to 07.96 07.96 07.96 07.96
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.6 ltr. - 74 kW 1.9 ltr. - 81 kW 1.9 ltr. - 66 kW 1.8 ltr. - 92 kW
TDI TDI
Ratio Final drive 37 : 9 = 4.111 37 : 10 = 3.700 35 : 9 = 3.889 37 : 9 = 4.111
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 37 : 17 = 2.176 35 : 18 = 1.944 35 : 19 = 1.842 36 : 17 = 2.118
3rd gear 39 : 30 = 1.300 38 : 31 = 1.226 37 : 32 = 1.156 40 : 28 = 1.429
4th gear 35 : 34 = 1.029 31 : 37 = 0.838 31 : 37 = 0.838 35 : 34 = 1.029
5th gear 31 : 37 = 0.838 28 : 41 = 0.683 28 : 41 = 0.683 31 : 37 = 0.838
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.444 2.527 2.656 3.444
Drive shaft flange ∅ 100 mm 130 mm 2) 130 mm 2) 108 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) France Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2) Drive shafts
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with triple rollertojoint
with respect the correctness of information in this document. Copyright by AUDI AG.

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters CTD CTE CTG CTJ
Manufactured from 11.94 11.94 11.94 11.94
to 07.96 07.96 03.95 03.95
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.6 ltr. - 74 kW 1.8 ltr. - 110 kw 2.6 ltr. - 110 kW 2.8 ltr. - 128 kW
Ratio Final drive 41 : 9 = 4.556 37 : 10 = 3.700 35 : 9 = 3.889 37 : 10 = 3.700
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 36 : 17 = 2.118 36 : 17 = 2.118 35 : 19 = 1.842 35 : 19 = 1.842

2 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters CTD CTE CTG CTJ
3rd gear 39 : 30 = 1.300 39 : 30 = 1.300 39 : 30 = 1.300 39 : 30 = 1.300
4th gear 33 : 35 = 0.943 35 : 34 = 1.029 33 : 35 = 0.943 33 : 35 = 0.943
5th gear 30 : 38 = 0.789 31 : 37 = 0.838 30 : 38 = 0.789 30 : 38 = 0.789
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.596 3.101 3.068 2.919
Drive shaft flange ∅ 100 mm 108 mm 130 mm 1) 130 mm 1)
Capacity 2.25 ltr.
Polygon bearings Yes Yes No No
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1) Drive shaft with triple
permitted roller
unless jointby AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters CWY CWZ CXX CXY
Manufactured from 11.94 01.95 11.94 01.95
to 03.95 07.96 03.95 07.96
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 2.8 ltr. - 128 kW 2.8 ltr. - 128 kW 2.6 ltr. - 110 kW 2.6 ltr. - 110 kW
Ratio Final drive 37 : 10 = 3.700 37 : 10 = 3.700 35 : 9 = 3.889 35 : 9 = 3.889
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 35 : 18 = 1.944 35 : 18 = 1.944 35 : 18 = 1.944 35 : 18 = 1.944
3rd gear 39 : 30 = 1.300 39 : 30 = 1.300 39 : 30 = 1.300 39 : 30 = 1.300
4th gear 33 : 35 = 0.943 33 : 35 = 0.943 33 : 35 = 0.943 33 : 35 = 0.943
5th gear 30 : 38 = 0.789 30 : 38 = 0.789 30 : 38 = 0.789 30 : 38 = 0.789
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 2.919 2.919 3.068 3.068
Drive shaft flange ∅ 130 mm 1) 130 mm 1) 130 mm 1) 130 mm 1)
Capacity 2.25 ltr.
Polygon bearings No Yes No Yes
1) Drive shaft with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters CZY 1) CZZ 1) DCM 2) 3) DCN 2)
Manufactured from 04.95 04.95 07.96 07.96
to 07.96 07.96 08.98 08.98
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.8 ltr. - 88 kW 2.6 ltr. - 102 kW 1.6 ltr. - 74 kW 1.6 ltr. - 74 kW
Ratio Final drive 37 : 9 = 4.111 35 : 9 = 3.889 37 : 9 = 4.111 41 : 9 = 4.556
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778 35 : 10 = 3.500
2nd gear 37 : 17 = 2.176 37 : 17 = 2.176 37 : 17 = 2.176 36 : 17 = 2.118
3rd gear 40 : 28 = 1.429 40 : 28 = 1.429 39 : 30 = 1.300 39 : 30 = 1.300
4th gear 36 : 33 = 1.091 35 : 34 = 1.029 35 : 34 = 1.029 33 : 35 = 0.943
5th gear 32 : 36 = 0.889 31 : 37 = 0.838 31 : 37 = 0.838 30 : 38 = 0.789
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.654 3.258 3.444 3.596

1. Gearbox identification 3
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters CZY 1) CZZ 1) DCM 2) 3) DCN 2)
Drive shaft flange ∅ 108 mm 130 mm 4) 100 mm 100 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) China, CIS
2) Magnesium gearbox housing
3) France
4) Drive shafts with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DDB DDK DDU1) DDZ
Manufactured from 11.95 03.96 07.96 01.96
to 07.96 07.96 08.98 07.96
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.8 ltr. - 92 kW 2.8 ltr. - 142 kW 1.8 ltr. - 92 kW 1.9 ltr. - 55 kW
TDI
Ratio Protected by copyright.Final drive 37 : 9 = 4.111 37 : 10 = 3.700
Copying for private or commercial purposes, in part or in whole, is not
37 : 9 = 4.111 37 : 9 = 4.111
Z2 : Z1 = i
permitted unless 1st gear 35 : 10 = 3.500 35or :accept
authorised by AUDI AG. AUDI AG does not guarantee 10 =any3.500
liability 34 : 9 = 3.778 34 : 9 = 3.778
with respect to the correctness of information in this document. Copyright by AUDI AG.
2nd gear 36 : 17 = 2.118 35 : 18 = 1.944 37 : 17 = 2.176 37 : 17 = 2.176
3rd gear 40 : 28 = 1.429 39 : 30 = 1.300 40 : 28 = 1.429 39 : 30 = 1.300
4th gear 35 : 34 = 1.029 33 : 35 = 0.943 35 : 34 = 1.029 32 : 36 = 0.889
5th gear 31 : 37 = 0.838 30 : 38 = 0.789 31 : 37 = 0.838 28 : 41 = 0.683
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.444 2.919 3.444 2.808
Drive shaft flange ∅ 108 mm 130 mm 2) 108 mm 130 mm 2)
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) Magnesium gearbox
2) Drive shaft with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DEM 1) DHC 2) DHE DHF
Manufactured from 10.95 07.96 07.96 07.96
to 12.95 08.98 08.98 08.98
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.8 ltr. - 88 kW 1.6 ltr. - 74 kW 1.6 ltr. - 74 kW 1.9 ltr. - 81 kW
TDI
Ratio Final drive 37 : 9 = 4.111 37 : 9 = 4.111 41 : 9 = 4.556 37 : 10 = 3.700
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 34 : 9 = 3.778 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 37 : 17 = 2.176 37 : 17 = 2.176 36 : 17 = 2.118 35 : 18 = 1.944
3rd gear 40 : 28 = 1.429 39 : 30 = 1.300 39 : 30 = 1.300 38 : 31 = 1.226
4th gear 36 : 33 = 1.091 35 : 34 = 1.029 33 : 35 = 0.943 31 : 37 = 0.838
5th gear 32 : 36 = 0.889 31 : 37 = 0.838 30 : 38 = 0.789 28 : 41 = 0.683
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.654 3.444 3.596 2.527

4 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DEM 1) DHC 2) DHE DHF
Drive shaft flange ∅ 108 mm 100 mm 100 mm 130 mm 2)
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) China, CIS
2) France
3) Drive shafts with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DHL DHM DHU DHW
Manufactured from 07.96 07.96 07.96 07.96
to 08.98 08.96 08.98 08.98
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.9 ltr. - 66 kW 1.8 ltr. - 92 kW 2.6 ltr. - 110 kW 1.8 ltr. - 110 kW
TDI 2.4 ltr. - 121 kW 1.8 ltr. - 132 kW
Ratio Final drive 35 : 9 = 3.889 37 : 9 = 4.111 35 : 9 = 3.889 37 : 10 = 3.700
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 35 : 18 = 1.944 36 : 17 = 2.118 35 : 18 = 1.944 36 : 17 = 2.118
3rd gear 38 : 31 = 1.226 40 : 28 = 1.429 39 : 30 = 1.300 39 : 30 = 1.300
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4th gear 31 : 37
with = 0.838
respect 35 : of34
to the correctness = 1.029
information 33 : 35Copyright
in this document. = 0.943 by AUDI35AG.: 34 = 1.029

5th gear 28 : 41 = 0.683 31 : 37 = 0.838 30 : 38 = 0.789 31 : 37 = 0.838

Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 2.656 3.444 3.068 3.100
Drive shaft flange ∅ 130 mm 1) 108 mm 130 mm 1) 108 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) Drive shaft with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DHX DHY DHZ DJA1)
Manufactured from 07.96 07.96 07.96 07.96
to 06.97 08.98 08.98 08.98
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 2.8 ltr. - 128 kW 2.8 ltr. - 142 kW 1.8 ltr. - 92 kW 1.8 ltr. - 88 kW
Ratio Final drive 37 : 10 = 3.700 37 : 10 = 3.700 37 : 9 = 4.111 37 : 9 = 4.111
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 35 : 18 = 1.944 35 : 18 = 1.944 37 : 17 = 2.176 37 : 17 = 2.176
3rd gear 39 : 30 = 1.300 39 : 30 = 1.300 40 : 28 = 1.429 40 : 28 = 1.429
4th gear 33 : 35 = 0.943 33 : 35 = 0.943 35 : 34 = 1.029 36 : 33 = 1.091
5th gear 30 : 38 = 0.789 30 : 38 = 0.789 31 : 37 = 0.838 32 : 36 = 0.889
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 2.919 2.919 3.444 3.654
Drive shaft flange ∅ 130 mm 2) 130 mm 2) 108 mm 108 mm
Capacity 2.25 ltr.

1. Gearbox identification 5
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DHX DHY DHZ DJA1)
Polygon bearings Yes Yes Yes Yes
1) China, CIS
2) Drive shafts with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DJB 1) DJE DUK DVN 2)
Manufactured from 07.96 07.96 08.98 08.98
to 06.97 08.98 09.01 09.01
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 2.6 ltr. - 102 kW 1.9 ltr. - 55 kW 1.9 ltr. - 85 kW 1.6 ltr. - 74 kW
TDI TDI
Ratio Final drive 35 : 9 = 3.889 37 : 9 = 4.111 32 : 9 = 3.556 37 : 9 = 4.111
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 34 : 9 = 3.778 35 : 10 = 3.500 34 : 9 = 3.778
2nd gear 37 : 17 = 2.176 37 : 17 = 2.176 35 : 18 = 1.944 37 : 17 = 2.176
3rd gear 40 : 28 = 1.429 39 : 30 = 1.300 33 : 27 = 1.222 39 : 30 = 1.300
4th gear 35 : 34 = 1.029 32 : 36 = 0.889 28 : 32 = 0.875 35 : 34 = 1.029
5th gear 31 : 37 = 0.838 28 : 41 = 0.683 24 : 35 = 0.686 31 : 37 = 0.838
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.258 2.808 2.438 3.444
Drive shaft flange ∅ 130 mm 3) 130 mm 3) 130 mm 3) 100 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) China, CIS
2) France
3) Drive shafts with triple roller joint

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Manual gearbox 5-speed 012/01W, front-wheel drive
with respect to the correctness of information in this document. Copyright by AUDI AG.

Code letters DVP DVS DVW DVX

Manufactured from 08.98 08.98 08.98 08.98
to 09.01 12.99 12.99 09.01
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.6 ltr. - 74 kW 1.9 ltr. - 66 kW 2.6 ltr. - 110 kW 1.8 ltr. - 110 kW
TDI 2.4 ltr. - 121 kW 1.8 ltr. - 132 kW
Ratio Final drive 41 : 9 = 4.556 35 : 9 = 3.889 35 : 9 = 3.889 37 : 10 = 3.700
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500
2nd gear 36 : 17 = 2.118 35 : 18 = 1.944 35 : 18 = 1.944 36 : 17 = 2.118
3rd gear 39 : 30 = 1.300 38 : 31 = 1.226 39 : 30 = 1.300 39 : 30 = 1.300
4th gear 33 : 35 = 0.943 31 : 37 = 0.838 33 : 35 = 0.943 35 : 34 = 1.029
5th gear 30 : 38 = 0.789 28 : 41 = 0.683 30 : 38 = 0.789 31 : 37 = 0.838
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.595 2.656 3.068 3.100
Drive shaft flange ∅ 100 mm 130 mm 1) 130 mm 1) 108 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes

6 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DVP DVS DVW DVX
1) Drive shaft with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DVZ DWA DWB 1) DWE
Manufactured from 08.98 08.98 08.98 08.98
to 09.01 04.01 04.01 06.00
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 2.8 ltr. - 142 kW 1.8 ltr. - 92 kW 1.8 ltr. - 88 kW 1.9 ltr. - 55 kW
TDI
Ratio Final drive 37 : 10 = 3.700 37 : 9 = 4.111 37 : 9 = 4.111 37 : 9 = 4.111
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 35 : 18 = 1.944 37 : 17 = 2.176 37 : 17 = 2.176 37 : 17 = 2.176
3rd gear 39 : 30 = 1.300 40 : 28 = 1.429 40 : 28 = 1.429 39 : 30 = 1.300
4th gear 33 : 35 = 0.943 35 : 34 = 1.029 36 : 33 = 1.091 32 : 36 = 0.889
5th gear 30 : 38 = 0.789 31 : 37 = 0.838 32 : 36 = 0.889 28 : 41 = 0.683
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 2.919 3.444 3.654 2.808
Drive shaft flange ∅ 130 mm 2) 108 mm 108 mm 130 mm 2)
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) China, CIS
2) Drive shafts with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DWF1) 2) DWG1) DWH 1) DWJ 3)
Manufactured from 08.98 08.98
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
08.98 08.98
permitted unless authorised by AUDI AG. AUDI AGto 12.98or accept any liability09.01
does not guarantee 09.01 02.01
with respect to the correctness of information in this document. Copyright by AUDI AG.
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.6 ltr. - 74 kW 1.6 ltr. - 74 kW 1.8 ltr. - 92 kW 2.8 ltr. - 142 kW
Ratio Final drive 37 : 9 = 4.111 41 : 9 = 4.556 37 : 9 = 4.111 35 : 9 = 3.889
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 35 : 10 = 3.500 34 : 9 = 3.778 35 : 10 = 3.500
2nd gear 37 : 17 = 2.176 36 : 17 = 2.118 37 : 17 = 2.176 35 : 18 = 1.944
3rd gear 39 : 30 = 1.300 39 : 30 = 1.300 40 : 28 = 1.429 38 : 31 = 1.226
4th gear 35 : 34 = 1.029 33 : 35 = 0.943 35 : 34 = 1.029 33 : 35 = 0.943
5th gear 31 : 37 = 0.838 30 : 38 = 0.789 31 : 37 = 0.838 30 : 38 = 0.789
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.444 3.596 3.444 3.068
Drive shaft flange ∅ 100 mm 100 mm 108 mm 130 mm 4)
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes

1. Gearbox identification 7
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters DWF1) 2) DWG1) DWH 1) DWJ 3)
1) Magnesium gearbox housing
2) France
3) South Africa
4) Drive shafts with triple roller joint

Manual gearbox 5-speed 012/01W, front-wheel drive

Code letters EAB EAE EEN EHV 1)
Manufactured from 01.99 01.99 08.98 11.98
to 09.01 09.01 01.00 09.01
Allocation Model Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ► Audi A4 1995 ►
Engine 1.9 ltr. - 66 kW 2.6 ltr. - 110 kW 1.9 ltr. - 81 kW 1.8 ltr. - 110 kW
TDI 2.4 ltr. - 121 kW TDI
Ratio Final drive 31 : 8 = 3.875 31 : 08 = 3.875 37 : 10 = 3.700 37 : 10 = 3.700
Z2 : Z1 = i 1st gear 35 : 10 = 3.500 35 : 10 = 3.500 35 : 10 = 3.500 34 : 9 = 3.778
2nd gear 35 : 18 = 1.944 35 : 18 = 1.944 35 : 18 = 1.944 37 : 17 = 2.176
3rd gear 38 : 31 = 1.226 39 : 30 = 1.300 38 : 31 = 1.226 40 : 28 = 1.429
4th gear 31 : 37 = 0.838 33 : 35 = 0.943 31 : 37 = 0.838 35 : 34 = 1.029
5th gear 28 : 41 = 0.683 30 : 38 = 0.789 28 : 41 = 0.683 31 : 37 = 0.838
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 2.646 3.059 2.527 3.100
Drive shaft flange ∅ 130 mm 2) 130 mm 2) 130 mm 2) 108 mm
Capacity 2.25 ltr.
Polygon bearings Yes Yes Yes Yes
1) For vehicles with electronic throttle
2) Drive shaft with triple roller joint

Manual gearbox 5-speed 5-speed 0A9,

012/01W, front- front-wheel drive
wheel drive 1)

Code letters FRS FSN 2)

Manufactured from 04.01 04.01
to 09.01 09.01
Allocation Model Audi A4 1995 ► Audi A4 1995 ►
Engine 1.8 ltr. - 92 kW 1.8 ltr. - 88 kW
Ratio Final drive 33 : 8 = 4.125 33 : 8 = 4.125
Z2 : Z1 = i 1st gear 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 37 : 17 = 2.176 37 : 17 = 2.176
3rd gear 40 : 28 by
Protected = 1.429 40 :for28private
copyright. Copying = 1.429
or commercial purposes, in part or in whole, is not

4th gear 35 with

: 34respect
= 1.029 36 : 33 = 1.091in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information
5th gear 31 : 37 = 0.838 32 : 36 = 0.889
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444
Overall ratio iov. in top gear 3.456 3.667
Drive shaft flange ∅ 108 mm 108 mm
Capacity 2.25 ltr.

8 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Manual gearbox 5-speed 5-speed 0A9,

012/01W, front- front-wheel drive
wheel drive 1)

Code letters FRS FSN 2)

Polygon bearings Yes Yes
1) Manual gearboxes 0A9 and 012/01W are identical.
2) China, CIS

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Gearbox identification 9
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2 Transmission layout
Identification and ratio

Note

-Arrows- point in direction of travel.

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Pinion shaft (output shaft)
6 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3 Calculating ratio „i“

Transmission ratio
Transmission ratio = No. of teeth on driv‐ : No. of teeth on
en gear drive gear

Ratios Formula
iG = Gear ratio ZG2 : ZG1
iA = Axle ratio ZA2 : ZA1
iov = Overall ratio iG x iA

Example:
5th gear Final drive
Drive gear ZG1 = 38 ZA1 = 10
Driven gear ZG2 = 30 ZA2 = 37

Calculations:
iG = 30 : 38 = 0.789
iA = 37 : 10 = 3.700 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
iov = 0.789 x 3.700 = 2.921
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Calculating ratio „i“ 11

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

4 Repair instructions

4.1 Contact corrosion!

♦ In addition to the manual gearboxes with aluminium housings,
the Audi A4 1995 is also fitted with a manual gearbox featuring
a magnesium alloy housing. Identification ⇒ page 12 .
♦ Bolts and other components coming into direct contact with
the gearbox housing have a surface coating that is designed
to be compatible with either aluminium or magnesium.
♦ On magnesium gearboxes, the bolts must always be replaced
on the following bolted connections: gearbox cover to gearbox
housing and cover for final drive to gearbox housing.
♦ If the incorrect components are used (bolts, nuts, washers
etc.), this will cause contact corrosion. The gearbox housing
will be damaged.
♦ The gearbox housing, gearbox cover and cover for final drive
must also all be made of the same material.
♦ If you are not sure whether used parts can be re-installed, al‐
ways fit new parts.

WARNING

♦ Only use Audi Genuine parts.

♦ Damage caused by contact corrosion is not covered under
warranty.

Identification of magnesium gearboxes:

The identification marking »Mg Al 9 Zn 1« can be found near
-arrow 1- and -arrow 2- on gearboxes with a magnesium housing.
The gearbox code letters
Protected also Copying
by copyright. indicate whether
for private a gearbox
or commercial has
purposes, a or in whole, is not
in part
magnesium housing ⇒ page 2 .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.2 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools catalogue .

12 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Gearbox
♦ Allocate bolts and other components according to gearbox
code letters, refer to ⇒ Electronic parts catalogue ⇒ page 2 .
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 78 .
♦ Capacities
⇒ „1.2 Code letters, allocation, transmission ratios, capaci‐
ties“, page 2 .
♦ For gear oil specification, refer to ⇒ Electronic parts cata‐
logue .
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing gearbox ensure dowel sleeves are correctly
seated.
Sealants
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Thoroughly clean housing contact surfaces beforepermitted
applyingunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sealing paste . with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Apply sealing paste -AMV 188 001 02- evenly and not too
thickly.
♦ Breather holes must remain free of sealing paste .
O-rings, oil seals and gaskets
♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and oil seals, always inspect the con‐
tact surface on the housing or shaft for burrs resulting from
removal or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease -G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing gaskets and oil seals, check and, if necessary,
top up oil level in gearbox ⇒ page 78 .

Locking elements

4. Repair instructions 13
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Do not over-stretch circlips.

♦ Installation position for some circlips: the circlip is fitted so that
the narrow part of the gap is at the top. This also gives the
pliers a better grip when removing and installing.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.

Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Loosen and tighten particularly sensitive
Protected parts
by copyright. infordiagonal
Copying se‐
private or commercial purposes, in part or in whole, is not
quence and in stages, taking careunless
permitted to keep them
authorised straight.
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then apply locking fluid -
AMV 185 101 A1- to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a thread tap or sim‐
ilar). Otherwise there is a danger of the bolts shearing off the
next time they are removed.

14 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Do not install shims which are damaged or not in perfect con‐
dition.
Bearings Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Install needle bearings so with
therespect
lettering
to the (side withof thicker
correctness informationmetal)
in this document. Copyright by AUDI AG.
faces towards the installing tool.
♦ Mark the needle bearings of 1st to 5th speed selector gears
when removing. This ensures the same installation position
when re-installing.
♦ Grease needle bearing for gearbox input shaft in flywheel.
♦ Lubricate all bearings in gearbox housing with gear oil before
installing.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Do not interchange the outer or inner races of bearings of the
same size (the bearings are paired).
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
Gear wheels, synchro-hubs, inner races for selector gears
♦ Before installing, heat inner races for selector gears to approx.
100° C using inductive heater -VAS 6414- .
♦ Use inductive heater -VAS 6414- to heat gear wheels and
synchro-hubs to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Note correct installation position.
Selector gears
♦ After installing, check that 1st to 5th speed selector gears have
an axial clearance of 0.15 ... 0.35 mm and check that they
rotate freely.
Synchro-rings
♦ Do not interchange synchro-rings. When reusing always fit to
the same selector gear.
♦ Check for wear; renew if necessary.
♦ Lubricate with gear oil when installing.
Checking synchro-rings with molybdenum coating

4. Repair instructions 15
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ The friction surface of an intact synchro-ring with molybdenum

coating has a graphite-grey, slightly porous appearance.
Clean the synchro-ring and make sure that the friction surface
is free of oil.
♦ The synchro-ring must be renewed if very shiny areas -A- have
formed on the friction surface or if the brass-coloured metal
underneath is already visible.

Abnormal wear on selector gears and locking collars

♦ Abnormal wear on synchro-ring or selector gear:
A - Worn chamfer on dog teeth of synchro-ring or selector gear

♦ In comparison: intact synchro-ring or selector gear:

B - Intact chamfer on dog teeth of synchro-ring or selector gear

♦ Abnormal wear on locking collar:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
C - Worn chamfer permitted
on internal splinesbyofAUDI
unless authorised locking collar
AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

16 Rep. gr.00 - Technical data

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ In comparison: intact locking collar:

D - Intact chamfer on internal splines of locking collar
Clutch actuation
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the clutch slave
cylinder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the clutch slave cylinder. As a
result the clutch slave cylinder will be destroyed.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures
⇒ „1.5 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 25 ).
♦ The clutch system should be bled at the same intervals as the
brake system.
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts consecutively in steps of 90° (1/4 turn each).
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Repair instructions 17
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

30 – Clutch
1 Servicing clutch mechanism
Overview
♦ ⇒ „1.1 Exploded view - pedal cluster (LHD vehicles)“,
page 18
♦ ⇒ „1.2 Removing and installing clutch pedal and over-centre
spring“, page 19
♦ ⇒ „1.3 Exploded view - pedal cluster (RHD vehicles)“,
page 21
♦ ⇒ „1.4 Exploded view - hydraulic system“, page 24
♦ ⇒ „1.5 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 25
♦ ⇒ „1.6 Function check for clutch master cylinder and slave
cylinder“, page 25
♦ ⇒ „1.7 Removing and installing clutch master cylinder“,
page 26
♦ ⇒ „1.8 Bleeding clutch system“, page 31
♦ ⇒ „2.2 Removing and installing clutch slave cylinder“,
page 35

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

Note

♦ Obtain radio code on vehicles

Protected by copyright. with coded
Copying radio.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Disconnect battery
withearth
respect strap with theof ignition
to the correctness switched
information in off.Copyright by AUDI AG.
this document.

♦ Lubricate all bearings and contact surfaces with polycarba‐

mide grease -G 052 142 A2- .
♦ Before working on pedal cluster, remove storage compartment
on driver's side ⇒ General body repairs, interior; Rep. gr. 68 .
♦ Make sure that no brake fluid escapes into the footwell, the
plenum chamber or onto the gearbox below. If this does hap‐
pen, clean the affected area thoroughly.
♦ When performing work in the footwell, put cloths on the carpet
to protect it from possible brake fluid spills.

1.1 Exploded view - pedal cluster (LHD vehicles)

18 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Mounting bracket
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46
2 - Pivot pin
❑ For clutch pedal and
brake pedal
❑ Installation position:
groove -arrow- towards
clutch pedal
3 - Retaining clip
4 - Hexagon socket head bolt
❑ 25 Nm
5 - Brake pedal
6 - Clutch pedal
❑ Removing and installing
⇒ page 19
7 - Pin
❑ Clip onto clutch pedal
8 - Retaining clip
9 - Clutch master cylinder
❑ Removing and installing
⇒ page 26
10 - Hexagon socket head bolt
❑ 20 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Mounting permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Insert in mounting
bracket with over-centre
spring
12 - Over-centre spring
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Remove and install with clutch pedal ⇒ page 19
13 - Hexagon socket head bolt
❑ 5 Nm
❑ Secures clutch and brake pedal pivot pin
14 - Seal
❑ Must not be removed
15 - TORX bolt
❑ 25 Nm
❑ Also secures brake master cylinder with brake servo

1.2 Removing and installing clutch pedal

and over-centre spring
Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .

1. Servicing clutch mechanism 19

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ Make sure that clutch pedal switch -arrow- is not pressed out
of retaining clip, as this would damage the thread of the switch
and the switch would have to be renewed.
♦ Clutch pedal switch -1- may only be fitted once so as to ensure
a firm fit.

– Detach clutch pedal from clutch master cylinder. To do this,

unclip pin using a screwdriver -arrow 1- and pull out pin
-arrow 2-.

– Press clutch pedal retaining clip -arrow 1- off pivot pin with a
screwdriver.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bolt -arrow 2-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press pivot pin for clutch pedal and brake pedal out to the right
until the clutch pedal can be removed.
– If necessary press brake pedal retaining clip off pivot pin with
a screwdriver.
– Take out clutch pedal and over-centre spring.
Installing
Installation is carried out in reverse sequence; note the following:

– Align pivot pin for clutch pedal/brake pedal so it protrudes out

of mounting bracket on clutch pedal side -arrow-.
– First engage clutch pedal in over-centre spring, then attach to
pivot pin.
– Connect clutch master cylinder to clutch pedal. Clip pin onto
clutch pedal.

20 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Do not tighten bolt -arrow 2- until both retaining clips have

been fitted on pivot pin for clutch pedal/brake pedal
(-arrow 1- for clutch pedal; retaining clip for brake pedal not
shown).

– Check setting of clutch pedal switch -1- above clutch pedal as

follows:
♦ Switch -1- must make full contact with clutch pedal -3- and be
fully actuated.
♦ Tolerance for adjustment: gap -a- between retaining clip and
mounting bracket -2- (or gap -b- on switch -1-) must not be
more than 0.5 mm.
♦ To adjust, hold retaining clip and turn clutch pedal switch -1-.

Note

Clutch pedal switch -F36- may only be fitted once so as to ensure

a firm fit.

1.3 Exploded view - pedal cluster (RHD vehicles)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing clutch mechanism 21

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Mounting bracket
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46
2 - Bearing bush
❑ Driving out ⇒ page 23
❑ Driving in ⇒ page 23
3 - Washer
4 - Brake pedal
❑ Bearing pin will only fit in
one position in bearing
bush
⇒ Item 13 (page 22)
5 - Hexagon socket head bolt
❑ 25 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Seal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Must not be removed
7 - Clutch master cylinder
❑ Removing and installing
⇒ page 26
8 - Hexagon socket head bolt
❑ 20 Nm
9 - Retaining clip
10 - Clutch pedal
❑ Removing and installing
⇒ page 19
11 - Needle bearing
❑ Pulling out ⇒ page 23
❑ Clamp in vice to press
in; use aluminium pro‐
tective jaw covers
12 - Cap
13 - Bearing bush
❑ With internal splines to accommodate pins of brake pedal and lever ⇒ Item 17 (page 22)
14 - Mounting
❑ Insert in mounting bracket with over-centre spring
15 - Over-centre spring
❑ For correct version, refer to ⇒ Electronic parts catalogue
16 - Bolt
❑ 25 Nm
❑ Self-locking
❑ Renew
17 - Lever
❑ Bearing pin will only fit in one position in bearing bush ⇒ Item 13 (page 22)
18 - TORX bolt
❑ 25 Nm
❑ Also secures brake master cylinder with brake servo

22 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

19 - Bolt
❑ 25 Nm

Knocking bush out of mounting bracket

Knocking bush into mounting bracket

– If the bush is very tight the mounting bracket must be suppor‐
ted in the area of the bore hole.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pulling out needle bearing

A - Internal puller 30 ... 37 mm , e.g. -Kukko 21/5-
B - Counter-support , e.g. -Kukko 22/2-

1. Servicing clutch mechanism 23

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1.4 Exploded view - hydraulic system

1 - Brake fluid reservoir

2 - Supply hose
❑ For clutch master cylin‐
der
3 - Pipe/hose assembly
❑ Allocation for LHD and
RHD vehicles ⇒ Elec‐
tronic parts catalogue
4 - Connecting nut for pipe
❑ 15 Nm
❑ New version has push-
on connection
5 - Mounting bracket
6 - Clutch pedal
❑ Removing and installing
⇒ page 19
7 - Hexagon socket head bolt
❑ 20 Nm
8 - Pin
❑ Apply polycarbamide
grease -G 052 142 A2-
9 - Clutch master cylinder
❑ Removing and installing
⇒ page 26
10 - Gearbox
11 - Clutch slave cylinder
❑ Removing and installing
⇒ page 35
❑ After working on hy‐
draulic clutch mecha‐
nism, bleed clutch system ⇒ page 31
❑ Do not operate clutch pedal after slave cylinder has been removed
12 - Bleeder valve
❑ Tighten to 4.5 Nm
❑ Follow correct procedure when bleeding ⇒ page 31
13 - Bracket
❑ Secured to gearbox
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Tightening torque ⇒ Item 2 (page 33)
with respect to the correctness of information in this document. Copyright by AUDI AG.

15 - Nut
❑ 2 Nm
16 - Gasket
17 - Seal
❑ Must not be removed

24 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1.5 Notes on removing and installing clutch

master cylinder and slave cylinder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective, you must first carry out
the appropriate function check
⇒ „1.6 Function check for clutch master cylinder and slave
cylinder“, page 25 .
♦ If the slave cylinder is removed from gearbox with the pipe/
hose assembly still attached, make sure you do not press the
clutch pedal. Otherwise, the piston will be pressed out of the
slave cylinder and be destroyed.
♦ After installing the slave cylinder, carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. The plunger of the slave cylinder is likely to have been
guided past the clutch release lever. The slave cylinder would
then be destroyed once pedal force exceeds approx. 300 N.

1.6 Function check for clutch master cylin‐

der and slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of theProtected
clutchbysystem can beforim‐
copyright. Copying private or commercial purposes, in part or in whole, is not
paired if the footwell trim or floor permitted
mats get trapped,
unless authorisedifbythe clutch
AUDI AG. AUDI AG does not guarantee or accept any liability
pedal switch jams or if the driver rests his foot on the clutch
with respect to the correctness of information in this document. Copyright by AUDI AG.

pedal for long periods of time.

Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
♦ If you identify any leaks you must renew the leaking compo‐
nent.

1. Servicing clutch mechanism 25

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Bleed clutch system ⇒ page 31 .

High pedal force:
♦ Clutch plate worn
♦ Mechanically defective pressure plate/clutch plate
⇒ page 39 .
Pedal forces:
- Clutch lining when new: approx. 115 N
- Clutch lining at wear limit: approx. 160 N
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 31 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.).
♦ Needle bearing in flywheel (centring bearing for input shaft)
defective, renew needle bearing ⇒ Rep. gr. 13 .
♦ Foreign body in clutch system.
♦ Mechanically defective pressure plate/clutch plate
⇒ page 39 .
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate).

1.7 Removing and installing clutch master

cylinder
Special tools and workshop equipment required
♦ Hose clamp -3094-

Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

If you suspect a defective clutch master cylinder, perform function

test prior to renewing
⇒ „1.5 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 25 .

Caution

♦ Follow steps required when disconnecting battery ⇒ Elec‐

trical system; Rep. gr. 27 .

– If fitted, remove cover over plenum chamber.

26 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– With the ignition switched off, disconnect battery earth strap

⇒ Electrical system; Rep. gr. 27 .
– Take the electronics box out of the plenum chamber as fol‐
lows:
Old version with assembly hole in cowl panel trim:
– Unscrew bolts -arrows- and take off the cover.

New version without assembly hole in cowl panel grille:

– Pull off retaining clip -1- and lift cowl panel trim -A- slightly.
Now remove bolt -arrow 2-.
– Remove remaining bolts -arrows- and pull off cover.
Both versions:
– Remove engine control unit; if necessary, remove auxiliary
relay carrier and auxiliary fuse box ⇒ Electrical
Protected system;
by copyright. Copying Rep.or commercial purposes, in part or in whole, is not
for private
gr. 97 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unplug connector from connector point.
– Pull engine wiring harness together with rubber grommet out
through opening in electronics box.

– Unscrew both nuts -A-.

– Lift electronics box off studs at rear and detach from securing
point -B-.

Note

♦ In the following steps make sure that no brake fluid escapes

into the plenum chamber or onto the gearbox below. If this
does happen, clean the affected area thoroughly.
♦ When performing work in the footwell, put cloths on the carpet
to protect it from possible brake fluid spills.

1. Servicing clutch mechanism 27

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Old version with aluminium clutch master cylinder:

– Clamp off supply hose -A- from brake fluid reservoir using
hose clamp -3094- . Disconnect hose from clutch master cyl‐
inder and plug hose.
– Remove rubber grommet from bulkhead above connecting
pipe for supply hose.
– Remove pipe -B- from clutch master cylinder and seal off.

New version with plastic clutch master cylinder:

– Clamp off supply hose -A- from brake fluid reservoir using
hose clamp -3094- . Disconnect hose from clutch master cyl‐
inder and plug hose.
– Remove rubber grommet from bulkhead above connecting
pipe for supply hose.
– Use screwdriver to prise out clip -C- and pull out pipe -B-
slightly.
Both versions:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove the two TORX bolts -arrows-.
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .

– Detach clutch pedal from clutch master cylinder. To do so, use

screwdriver to prise out pin locking element -arrow 1-, pull out
pin -arrow 2- and press out clutch pedal.

28 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ When performing the following steps, make sure clutch pedal

does not press the clutch pedal switch -1- out of the retaining
clip, as this would damage the thread of the switch and the
switch would have to be renewed.
♦ Switch may only be fitted once so as to ensure a firm fit.

– Unscrew securing bolts for clutch master cylinder -arrow 2-

and mounting bracket -arrow 3-.
– Pull entire pedal cluster slightly towards passenger compart‐
ment and take out clutch master cylinder -4-.
Installing
Installation is carried out in reverse sequence; note the following:

For aluminium clutch master cylinder with adjustable push rod

joint only:
– When renewing clutch master cylinder, check distance -a- at
push rod joint (extended) and adjust if necessary.
♦ LHD: Dimension -a- = 165 ± 0.5 mm
♦ RHD: Dimension -a- = 139 ± 0.5 mm
All versions:

– Fit clutch master cylinder so that seal -1- makes full surface
contact with washer behind mounting bracket and tighten bolts
-2- to 20 Nm.
– Press guide -arrow A- on connecting pipe -3- into recess
-arrow B- on mounting bracket.
A second mechanic is required for the next step.

– Slide complete pedal cluster forwards towards bulkhead, fit

bolt -arrow 3- and tighten it by hand. Have second mechanic
guide connecting pipe into clutch master cylinder from plenum
chamber.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing clutch mechanism 29

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Tighten bolts for brake servo -arrows- to 25 Nm.

Old version with aluminium clutch master cylinder:

– Tighten pipe union nut -B- to 15 Nm at clutch master cylinder.
– Fit rubber grommet over connecting pipe for supply hose -A-
in bulkhead.
– Push supply hose -A- from brake fluid reservoir on as far as it
will go.
– Detach hose clamp -3094- from supply hose -A-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

New version with plastic clutch master cylinder:

– Press in retaining clip -C- as far as it will go.
– Push pipe -B- into clutch master cylinder until it engages au‐
dibly.
– Fit rubber grommet -D- on connecting pipe for supply hose
-A- in bulkhead.
– Push supply hose -A- from brake fluid reservoir on as far as it
will go.
– Detach hose clamp -3094- from supply hose -A-.
All versions:

– Tighten hexagon socket head bolt -arrow- securing pedal clus‐

ter to central tube for dash panel to 25 Nm.
– Connect clutch master cylinder to clutch pedal. Clip pin onto
clutch pedal.
– After installing clutch master cylinder, bleed clutch system
⇒ page 31 .

30 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Check setting of clutch pedal switch -1- over clutch pedal as

follows:
♦ Switch -1- must make full contact with clutch pedal -3- and be
fully actuated.
♦ Tolerance for adjustment: gap -a- between retaining clip and
mounting bracket -2- (or gap -b- on switch -1-) must not be
more than 0.5 mm.
♦ To adjust, hold retaining clip and turn clutch pedal switch -1-.

Note

Clutch pedal switch -F36- may only be fitted once so as to ensure

a firm fit.

– Install storage compartment on driver's side ⇒ General body

repairs, interior; Rep. gr. 68 .

– Always renew gasket -C-.

– Make sure gasket does not conceal opening in body and
raised metal edge.
– Fit electronics box at attachment point -B- and tighten nuts
-A- to 4 Nm.
– Press on cover hand-tight and tighten bolts in a diagonal se‐
quence to 4 Nm (also see marking on cover).
– Route engine wiring harness and plug in connector in con‐
nector console.
– Install engine control unit and, if removed, also auxiliary relay
carrier and auxiliary fuse box ⇒ Electrical system; Rep. gr.
97 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. gr. 27 .

1.8 Bleeding clutch system

Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234- or brake fill‐
ing and bleeding equipment -V.A.G 1869-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Brake fluid specification ⇒ Brake system; Rep. gr. 47 .

1. Servicing clutch mechanism 31

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Procedure

Note

♦ The clutch system must be bled after performing work on the

hydraulic clutch mechanism.
♦ Before bleeding the clutch system, pull back the clutch pedal
to the normal position and top up brake fluid to „Max“ marking
on brake fluid reservoir.
♦ Open the bleeder valve before switching on the bleeding ap‐
pliance.
♦ When performing the following steps, make sure that no brake
fluid escapes onto the gearbox.
♦ The clutch system should be bled at the same intervals as the
brake system.

– Connect brake filling and bleeding equipment -V.A.G 1869- or

-VAS 5234- , but do not switch on at this stage ⇒ Brake sys‐
tem; Rep. gr. 47 ; Bleeding brake system .
– If fitted, remove noise insulation beneath gearbox.
– Connect bleeder hose -A- to slave cylinder -arrow- and open
bleeder valve.
– Connect bleeder hose to pressure hose of fluid collector bottle.
– Switch on bleeding appliance and allow about 100 cm3 of
brake fluid to drain out.
♦ Operating pressure 2.0 bar

Note

♦ Ensure bleeder hose is correctly fitted during bleeding opera‐

tion.
♦ Do not allow brake fluid to come into contact with the gearbox.

– Close bleeder valve; tightening torque: 4.5 Nm.

– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
– Disconnect bleeder hose and fit protective cap.
– Remove brake filling and bleeding equipment -VAS 5234- or
-V.A.G 1869- from brake fluid reservoir.
– If originally fitted, install noise insulation beneath gearbox.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

32 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2 Servicing clutch release mechanism

Overview:
♦ ⇒ „2.1 Exploded view - clutch release mechanism“,
page 33
♦ ⇒ „2.2 Removing and installing clutch slave cylinder“,
page 35

2.1 Exploded view - clutch release mechanism

1 - Clutch slave cylinder

❑ Do not operate clutch
pedal after slave cylin‐
der has been removed
❑ Removing and installing
⇒ page 35
❑ Press in slave cylinder
so that securing bolt can
be fitted easily
❑ Grease lightly before in‐
stalling ⇒ page 37
❑ Disconnecting pipe/
hose assembly
⇒ page 37
❑ Follow correct proce‐
dure when bleeding
⇒ page 31
❑ Tighten bleeder valve to
4.5 Nm
2 - Bolt
❑ Apply locking fluid -
D 185 400 A2- to hexa‐
gon bolt when fitting
❑ Tighten to 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Hexagon socket head permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
bolt is self-locking with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Renew
❑ Tighten to 23 Nm
3 - Bracket
❑ For pipe/hose assembly
❑ Attached to gearbox to‐
gether with slave cylin‐
der
❑ Installing ⇒ page 37
4 - Plunger
❑ Lubricate end of plunger with copper grease (commercially available)
5 - Dished spring
❑ Smaller diameter (convex side) faces guide sleeve
6 - Input shaft oil seal
❑ Pull out of guide sleeve using oil seal extractor lever -VW 681- or puller hook -T20143-
❑ Knock in onto stop with drift sleeve -VW 192-
7 - Torx socket head bolt
❑ Self-locking

2. Servicing clutch release mechanism 33

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

❑ Renew
❑ Black: only for aluminium gearboxes
❑ Bright metal: for aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Tighten to 35 Nm on aluminium gearboxes
❑ Tighten to 25 Nm on magnesium gearboxes
8 - Release bearing
❑ With or without plastic ring, depending on design
❑ Checking and servicing release bearing with glued plastic ring ⇒ page 35
❑ Checking release bearing with mechanically attached plastic ring ⇒ page 35
❑ Renew if groove worn on plastic ring is too deep ⇒ page 35
❑ Do not wash out bearing; wipe clean only
❑ Renew bearing if noisy
❑ Retainer lugs on release bearing must engage in release lever
9 - Clutch release lever
❑ Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease
(commercially available).
10 - Retaining spring
❑ Secure to clutch release lever
11 - Guide sleeve
❑ Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal
⇒ Item 6 (page 33)
❑ Installation position: Oil drain hole points
Protected by downwards
copyright. Copying(if
for fitted)
private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Guide sleeve is made of different materials
with respect tofor
the aluminium and magnesium
correctness of information gearboxes
in this document. Copyright by AUDI AG.

❑ For correct version, refer to ⇒ Electronic parts catalogue

12 - O-ring
❑ Renew
13 - Intermediate piece
14 - Ball-head pin
❑ Ball-head pin is made of different materials for aluminium and magnesium gearboxes
❑ Lubricate with MoS2 grease
❑ Tighten to 25 Nm on aluminium gearboxes
❑ Tighten to 18 Nm on magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
15 - Gearbox

34 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Checking and servicing release bearing with glued plastic ring

• Identification: inner side of plastic ring has three lugs
-arrows-.
The plastic ring -arrows- may come loose from the release bear‐
ing when the gearbox or release bearing is removed. The release
bearing does not have to be renewed if this happens.
– Before installing the gearbox, glue the loose plastic ring back
onto the bearing with adhesive -AMV 195 KD1 01- .
• The three square lugs -arrows- on the plastic ring engage in
the recesses of the bearing ring.

Note

The release bearing must be renewed if the groove worn on the

plastic ring is deeper than 0.8 mm.

Checking release bearing with mechanically attached plastic ring

• Identification: retaining tabs around plastic ring -arrows-.

Note

♦ The release bearing must be renewed if the plastic ring -1- has
come loose.
♦ The release bearing -3- must be renewed if the groove
-arrow 2- worn on the plastic ring
Protected -1- is deeper
by copyright. Copying forthan
private0.8 mm. purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 Removing and installing clutch slave

cylinder
Special tools and workshop equipment required
♦ Hose clamps, up to Ø 25 mm -3094-

♦ Lithium grease -G 052 150 A2-

♦ Copper grease (commercially available)

2. Servicing clutch release mechanism 35

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Removing clutch slave cylinder

Note

♦ If you suspect a defective clutch master cylinder, perform

function test prior to renewing
⇒ „1.5 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 25 .
♦ Do not allow brake fluid to come into contact with the gearbox.
If necessary, clean the gearbox housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cautionpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Make sure you do not press the clutch pedal if the clutch slave
cylinder is removed from the gearbox with the pipe/hose as‐
sembly still attached. Otherwise, the piston will be pressed out
of the slave cylinder and be destroyed.

– If fitted, remove noise insulation beneath gearbox.

Vehicles with 6-cylinder engine:
– Disconnect exhaust system at clamp (left-side) -left arrow-.

Note

Flexible element in front exhaust pipe must not be bent more than
10° - otherwise it can be damaged.

– Remove heat shield for drive shaft (left-side).

– Remove front exhaust pipe with catalytic converter (left-side)
⇒ Engine, mechanics; Rep. gr. 26 .

Continued for all vehicles:

– Remove bolt -arrow- and take out clutch slave cylinder from
the rear.

Caution

Do not depress clutch pedal after removing slave cylinder. The

slave cylinder would then be destroyed once pedal force ex‐
ceeds approx. 300 N.

36 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Using hose clamp -3094- , clamp off pipe/hose assembly.

– Release retaining clip -A- using a screwdriver and pull out to
limit stop.
– Detach pipe/hose assembly from clutch slave cylinder.
Installing clutch slave cylinder
Installation is carried out in reverse sequence; note the following:

Note

♦ Do not allow brake fluid to come into contact with the gearbox.
If necessary, clean the gearbox housing.
♦ If the clutch slave cylinder is inserted at an angle, there is a
danger that the operating rod will be guided past the clutch
release lever.
♦ When installing, press in slave cylinder so that securing bolt
can be fitted easily.
♦ Renew securing bolt for slave cylinder.

– Before inserting clutch slave cylinder into gearbox housing,

lubricate area -a- of sleeve with lithium grease -G 052 150 A2- .
– Using copper grease (commercially available), lightly lubricate
surface where plunger and clutch release lever make contact.

– If fitted, attach bracket -3- for hose/pipe assembly to clutch

slave cylinder -4-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Servicing clutch release mechanism 37

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Guide slave cylinder -1- into mounting hole in gearbox hous‐

ing, keeping it as far as possible in line with the operating
direction of the plunger -arrow A-.
– At the same time insert in recess -arrow B- on clutch release
lever -3-.
– Secure slave cylinder -1- with new bolt -2-. Tightening torque
⇒ Item 2 (page 33)

Note

If the slave cylinder is inserted at an angle, there is a danger that

the plunger -arrow A- will be guided past the recess -arrow B- on
the clutch release lever.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– To connect pipe to clutch slave cylinder, press in retaining clip

-A- as far as it will go.
– Push pipe -B- into clutch slave cylinder until it engages audibly.
– Pull pipe/hose assembly to check that it is securely seated.

Caution

♦ After installing the slave cylinder carefully press the clutch

pedal.
♦ If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down
further.
♦ The plunger of the slave cylinder is likely to have been
guided past the clutch release lever.
♦ The slave cylinder would then be destroyed once pedal
force exceeds approx. 300 N.
♦ For comparison: normal pedal force is approx. 115 N.

Vehicles with 6-cylinder engine:

– Install front exhaust pipe and ensure stress-free alignment of
exhaust system ⇒ Engine, mechanics; Rep. gr. 26 .
– Install heat shield for drive shaft (left-side).
Continued for all vehicles:
– If the pipe-hose assembly was disconnected at the slave cyl‐
inder, the clutch system has to be bled after installing slave
cylinder ⇒ page 31 .
– If originally fitted, install noise insulation beneath gearbox.
Tightening torques
Component Nm
Heat shield for drive shaft to gearbox 23

38 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3 Servicing clutch
Overview
♦ ⇒ „3.1 Exploded view - clutch unit“, page 39
♦ ⇒ „3.2 Removing and installing clutch“, page 41

Note

♦ Refer to general repair instructions ⇒ page 12 .

♦ Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).
♦ Renew clutch plate and pressure plate if riveted fastening is
damaged or loose.
♦ Select the correct clutch plate and pressure plate according to
engine code ⇒ Electronic parts catalogue .
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.
♦ Pressure plates have an anti-corrosion coating and are
greased. Only the contact surface may be cleaned, otherwise
the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.

3.1 Exploded view - clutch unit

Note

♦ The gearbox has to be removed before working on the clutch ⇒ page 65 .

♦ If components are marked, coloured marking on dual mass flywheel must be aligned with coloured marking
on pressure plate.

3. Servicing clutch 39
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Flywheel/dual mass fly‐

wheel
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13
2 - Bolt for flywheel
❑ Renew
❑ Vehicles without dual
mass flywheel: 60 Nm +
turn 90° further
❑ Vehicles with dual mass
flywheel: 60 Nm + turn
180° further
3 - Clutch plate
❑ Installation position:
Clutch lining must make
full contact with flywheel
❑ The marking
„Getriebeseite“ (gear‐
box side), if provided,
faces towards pressure
plate/gearbox
❑ Coil springs (damper
assembly) point to‐
wards pressure plate
and gearbox
❑ Select diameter of
clutch plate according to
engine code ⇒ Elec‐
tronic parts catalogue
❑ Centralising ⇒ page 42
❑ Lightly grease splines ⇒ page 39
4 - Pressure plate
❑ Removing and installing ⇒ page 41
❑ Checking ends of diaphragm spring ⇒ page 41
❑ Checking spring connection and rivets ⇒ page 41
❑ Checking wire ring ⇒ page 41
5 - Bolt
❑ 22 Nm
Observe tightening sequence ⇒ page 42

6 - Needle bearing
❑ Check for damage or wear
❑ Driving in and driving out ⇒ Engine, mechanics; Rep. gr. 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

40 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.

Note

When performing repairs always match up clutch pressure plate

and clutch plate by checking engine code ⇒ Electronic parts
catalogue .

Checking spring connections and rivets

– Check spring connection between pressure plate and cover
-centre arrow- for cracks and make sure rivet fastenings
-right arrows- are seated tightly.
• Renew pressure plate if spring connections are broken or bad‐
ly bent, or if riveted fastenings are loose.

Checking wire ring

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– with
Check
respectthat
to the wire ringofininformation
correctness pressure plate
in this -arrow-
document. is not
Copyright damaged.
by AUDI AG.

• Renew pressure plate if wire ring is broken.

3.2 Removing and installing clutch

Special tools and workshop equipment required
♦ Counterhold tool -3067-

3. Servicing clutch 41
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Centring mandrel -3176-

♦ Grease for clutch plate splines -G 000 100-

Removing
– Attach counterhold tool -3067- before loosening bolts.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Loosen all bolts consecutively in clockwise direction and in
steps of 90° (1/4 turn) until the pressure plate is released.
Installing
– Re-position counterhold tool -3067- to tighten bolts.
• Installation position of clutch plate: coil springs (damper as‐
sembly) or marking „Getriebeseite“ point towards pressure
plate and gearbox.
– Use centring mandrel -3176- to centralise clutch plate.
To prevent the pressure plate from becoming distorted during in‐
stallation (causes clutch grab when driving off), always adhere to
the following procedure when installing the pressure plate:
– Position pressure plate on centring pins.
– Screw in all bolts evenly by hand until bolt heads make contact
with pressure plate.
– Tighten all bolts consecutively in clockwise direction and in
steps of 90° (1/4 turn) until housing makes contact with fly‐
wheel.
– Tighten all bolts to final torque (22 Nm) consecutively in Protected
clock‐ by copyright. Copying for private or commercial purposes, in part or in whole, is not
wise direction. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

42 Rep. gr.30 - Clutch

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

34 – Controls, housing
1 Servicing gear selector mechanism
for vehicles up to 05.99
Identification: gear lever must be pressed down when engaging
reverse gear.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

Servicing gear selector mechanism for vehicles from 05.99 on‐

wards ⇒ page 55

Overview
♦ ⇒ „1.1 Exploded view - standard-travel selector mechanism“,
page 43
♦ ⇒ „1.2 Removing and installing standard-travel selector mech‐
anism“, page 45
♦ ⇒ „1.3 Adjusting standard-travel selector mechanism“,
page 45
♦ ⇒ „1.4 Exploded view - servicing short-travel selector mecha‐
nism“, page 47
♦ ⇒ „1.5 Removing and installing short-travel selector mecha‐
nism“, page 50
♦ ⇒ „1.6 Adjusting short-travel selector mechanism“, page 51

1.1 Exploded view - standard-travel selector mechanism

Note

♦ Lubricate all bearings and moving surfaces. Select correct type of grease from ⇒ Electronic parts catalogue .
♦ Adjusting standard-travel selector mechanism ⇒ page 45

1. Servicing gear selector mechanism for vehicles up to 05.99 43

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Bolt
❑ 23 Nm
❑ Self-locking
❑ Always renew
2 - Selector rod
❑ With selector joint
3 - Bush
❑ Installation position:
rounded end faces gear
lever
4 - Spring
5 - Ball stop
❑ Insert spring and bush in
ball stop and fit on gear
lever so that spring and
bush are on the right
when looking forwards
❑ Install before fitting cir‐
clip
⇒ Item 21 (page 44)
6 - Spring
7 - Spacer bush
8 - Circlip
❑ Do not overstretch when
fitting
9 - Rubber ring
10 - Bush Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
11 - Cross-head screw
with respect to the correctness of information in this document. Copyright by AUDI AG.

12 - Mounting frame (bottom

section)
13 - Mounting frame (top section)
14 - Boot
❑ Retaining hook on rear of cover; pry out carefully from centre console
15 - Bush
16 - Gear knob
17 - Gear lever
❑ Can only be fitted into ball housing in one position
18 - Nut
❑ 23 Nm
19 - Spacer tube
20 - Connecting piece
21 - Circlip
❑ Renew
❑ Take out before removing ball stop
❑ Installation position: rounded side faces ball housing ⇒ Item 22 (page 44)
22 - Ball housing
❑ Limit pieces for ball stop on left and right must be engaged
❑ Installation position: reverse detent faces left

44 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

23 - Buffer
24 - Nut
❑ 10 Nm
25 - Selector mechanism housing
26 - Boot
❑ Remove heat shield before removing and installing
❑ Pull carefully over selector rod
27 - Nut
❑ 10 Nm
❑ Self-locking
❑ Renew
28 - Bolt
29 - Selector fork
❑ Before dismantling, detach heat shield and push towards rear
30 - Bolt
❑ 23 Nm
31 - Clamp

1.2 Removing and installing standard-travel

selector mechanism
Removing
– Remove heat shield.
– Pull boot -7- downwards off bottom of selector mechanism.
– Slacken nut -1- securing selector fork to gear lever.
– Remove bolt -8- from selector fork.
– Remove gear knob and gear lever boot.
– Detach noise insulation.
– Unscrew nuts -3- and -4- securing ball housing and remove
the two connecting pieces -2- and-5-.
– Lift ball housing -6- out of centre console together with gear
lever.
Installing
Installation is carried out in reverse sequence; note the following:
– Push selector rod on so that the securing bolt fits in the recess
in the selector shaft.
Tightening torques
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Component Nm
Ball housing to selector mechanism housing 23
Selector fork to gear lever 10
Selector rod to selector fork 23

1.3 Adjusting standard-travel selector

mechanism
The following are prerequisites for correct gear lever alignment:

1. Servicing gear selector mechanism for vehicles up to 05.99 45

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

• Gear selector linkage must be in proper condition and undam‐

aged.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
– Remove heat shield.
– Loosen bolt -arrow- securing selector rod.
– Remove gear knob and gear lever boot.
– Detach noise insulation.

– Loosen nuts -1- for ball housing.

– Align ball housing -2- horizontally.
– Tighten nuts for ball housing to 23 Nm.

– Adjust gear lever as follows:

♦ Gear lever vertical
♦ Distance -a- between ball stop buffersProtected
and ball housing
by copyright. should
Copying for private or commercial purposes, in part or in whole, is not
be equal on both sides. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The illustration shows the gear lever from behind (looking towards
the front of the vehicle).

– Align gear lever so that it is angled slightly to the rear.

– Hold gear lever in this position (second mechanic required).
– Tighten bolt securing selector rod under vehicle to 23 Nm.

Note

The gear lever must remain in the same position while the bolt is
being tightened.

– Install heat shield.

46 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1.3.1 Checking gear lever adjustment

• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Depress clutch.
– Check that all gears can be engaged.
– Check operation of reverse gear lock.
– Put gear lever into the 5th/reverse gear gate and move gear
lever towards reverse gear (without applying excessive pres‐
sure on the gear lever).
♦ The amount of travel until contact is made with reverse gear
lock should measure 5 ... 10 mm (measured at gear knob).
– Reduce pressure on gear lever to let it move back.
♦ The gear lever should return by itself from the 5th/reverse gear
gate into the 3rd/4th gear gate.
– Check fine adjustment if necessary.
Fine adjustment
• If the gear lever setting is incorrect it can be adjusted as fol‐
lows:
– Loosen nuts for ball housing.
– Move gear lever with ball housing to the right towards 5th/re‐
verse gate as far as the stop in the gearbox, and hold in this
position.
– When doing this push the ball housing to left against the gear
lever.
– Then hold gear lever and ball housing in this position and
tighten.
– Fit boot and gear knob.

Note

If only 5th gear and reverse gear cannot be engaged, check the
5th and reverse gear locking unit and renew if necessary
⇒ page 97 .

1.4 Exploded view - servicingpermitted

short-travel selector mechanism
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ Lubricate all bearings and moving surfaces. Select correct type of grease from ⇒ Electronic parts catalogue .
♦ Adjusting selector mechanism ⇒ page 51
♦ To remove the entire selector mechanism, first remove exhaust system ⇒ Engine, mechanics; Rep. gr. 26 .
♦ To dismantle selector mechanism without removing from vehicle, lower selector mechanism housing.

1. Servicing gear selector mechanism for vehicles up to 05.99 47

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Gear knob
2 - Bush
3 - Boot
❑ Retaining hook on rear
of cover; pry out careful‐
ly from centre console
4 - Mounting frame (top sec‐
tion)
5 - Mounting frame (bottom
section)
6 - Bush
7 - Sleeve
8 - Circlip
❑ Do not overstretch when
fitting
9 - Spacer bush
10 - Spring
11 - Ball stop
❑ Insert spring and bush in
ball stop and fit on gear
lever so that spring and
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
bush are on the right with respect to the correctness of information in this document. Copyright by AUDI AG.
when looking forwards
❑ Install before fitting cir‐
clip
⇒ Item 23 (page 48)
12 - Spring
13 - Bush
❑ Installation position:
rounded end faces gear
lever
14 - Gear lever
❑ Can only be fitted into ball housing in one position
15 - Spacer tube
16 - Nut
❑ 8 Nm
17 - Nut
❑ 8 Nm
18 - Noise insulation
19 - Nut
❑ M6 - 10 Nm
❑ M8 - 23 Nm
20 - Connecting piece
21 - Nut
❑ 23 Nm
22 - Connecting piece
23 - Circlip
❑ Renew
❑ Take out before removing ball stop

48 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

❑ Installation position: rounded side faces ball housing ⇒ Item 25 (page 49)
24 - Buffer
25 - Ball housing
❑ Limit pieces for ball stop on left and right must be engaged
❑ Installation position: reverse detent faces left
26 - Push rod (rear)
27 - Bolt
❑ 10 Nm
28 - Bolt
❑ 23 Nm
29 - Washer
30 - Selector mechanism housing
31 - Nut
❑ 10 Nm
32 - Bolt
33 - Nut
❑ 10 Nm
❑ Self-locking
❑ Renew
34 - Selector fork
35 - Bolt
❑ 23 Nm
36 - Clamp
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
37 - Selector
permitted rod (front)
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ With selector joint
with respect to the correctness of information in this document. Copyright by AUDI AG.

38 - Bolt
❑ 23 Nm
❑ Self-locking
❑ Renew
39 - Push rod (front)
❑ To avoid tension, first secure push rod (front) to selector mechanism housing and push rod (rear)
❑ Counterhold bolt ⇒ Item 42 (page 49) when tightening nut ⇒ Item 41 (page 49)
❑ Securing push rod from 06.96 onwards ⇒ page 50
40 - Bolt
❑ 40 Nm
41 - Nut
❑ 40 Nm
42 - Bolt
43 - Bracket for push rod
❑ Illustration shows method of securing push rod up to 05.96
❑ Securing push rod from 06.96 onwards ⇒ page 50
44 - Tensioning ring
45 - Boot
❑ Remove catalytic converter and heat shield before removing and installing
❑ Carefully pull over selector rod and push rod

1. Servicing gear selector mechanism for vehicles up to 05.99 49

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

❑ Align with markings on selector rod and push rod when installing

Securing push rod on gearbox from 06.96 onwards

From 06.96 onwards, push rod is bolted directly onto gearbox.
Additional bracket ⇒ Item 43 (page 49) and bolts for bracket have
been discontinued. The gearbox cover has been modified ac‐
cordingly and now has an additional mounting boss.
A - Hexagon socket head bolt, 40 Nm
B - Sleeve, convex side faces push rod
C - Bonded rubber bush
D - Push rod (front)
E - Washer

1.5 Removing and installing short-travel se‐

lector mechanism
Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove gear
with respect knob
to the and gear
correctness leverinboot.
of information this document. Copyright by AUDI AG.

– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 .
– Detach noise insulation.
– Remove noise insulation for selector mechanism housing
-arrows-.

– Remove nuts securing selector mechanism housing

-arrows-.
– Remove rear section of exhaust system (rearward of clamp(s))
and, if necessary, front exhaust pipe with catalytic converter
⇒ Engine, mechanics; Rep. gr. 26 .
– Remove heat shield.

50 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Remove selector rod -arrow A-.

– Unscrew hexagon socket head bolt on push rod -arrow B-.
– Pivot selector mechanism housing downwards with selector
rod and push rod, and remove.
Installing
Installation is carried out in reverse sequence; note the following:
– Push selector rod on so that the new securing bolt fits in the
recess in the selector shaft.

– Then secure selector rod -arrow A-.

– Then bolt push rod to gearbox -arrow B-.
– Adjust selector mechanism ⇒ page 51 .
– Install heat shield.
– Install exhaust system so it is free of stress ⇒ Engine, me‐
chanics; Rep. gr. 26 .
Tightening torques
Component Nm
Selector housing to body 10
Push rod to gearbox 40
Selector rod to gearbox 23 1)
• 1) Renew bolt.

1.6 Adjusting short-travel selector mecha‐

nism
The following are prerequisites for correct gear lever alignment:
• Gear selector linkage must be in proper condition and undam‐
aged.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
– Remove gear knob and gear lever boot.
– Remove noise insulation for selector mechanism housing
-arrows-.
– Measure distance between body and rear push rod (in selector
mechanism).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing gear selector mechanism for vehicles up to 05.99 51

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Specification: distance -a- = 37 mm

– If distance measured is not correct, adjust dimension -a- as
follows:

– Loosen bolt -arrow 2- for push rod.

♦ Rear push rod (in selector mechanism) should move freely in
both directions on slide.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Set to distance -a- by moving rear push rod (in selector mech‐
anism).
– Tighten push rod bolt to 23 Nm.

– Loosen nuts for ball housing nuts -arrow A- and -arrow B-.
– Align ball housing ⇒ Item 25 (page 49) horizontally.
– Tighten nuts for ball housing: -arrow A- to 25 Nm and
-arrow B- to specified torque ⇒ Item 19 (page 48) .

52 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Slacken bolt -arrow- for selector rod.

♦ Connection between selector rod and selector mechanism
should move freely.
– Align gear lever so that it is positioned slightly to the rear.

♦ Distance -a- between ball stop buffers and ball housing should
be equal on both sides.
– Hold gear lever in this position (second mechanic required).
– Tighten bolt for selector rod to 23 Nm.

Note

The gear lever must remain in the same position while the bolt is
being tightened.

1.6.1 Checking gear lever adjustment

• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Depress clutch.
– Check that all gears can be engaged.
– Check operation of reverse gear lock.
– Put gear lever into the 5th/reverse gear gate and move gear
lever towards reverse gear (without applying excessive pres‐
sure on the gear lever).
♦ The amount of travel until contact is made with reverse gear
lock should measure 5 ... 10 mm (measured at gear knob).
– Reduce pressure on gear lever to let it move back.
♦ The gear lever should return by itself from the 5th/reverse gear
gate into the 3rd/4th gear gate.
– Check fine adjustment if necessary.
Fine adjustment Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• If the gear lever setting is incorrect it can be adjusted as fol‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

lows:

1. Servicing gear selector mechanism for vehicles up to 05.99 53

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Loosen nuts for ball housing nuts -arrow A- and -arrow B-.
– Move gear lever with ball housing to the right towards 5th/re‐
verse gate as far as the stop in the gearbox, and hold in this
position.
– When doing this push the ball housing to left against the gear
lever.
– Then hold gear lever and ball housing in this position and
tighten nuts for ball housing. Tightening torques: -arrow A- to
25 Nm and -arrow B- to specified torque
⇒ Item 19 (page 48) .
– Fit boot and gear knob.

Note

If only 5th gear and reverse gear cannot be engaged, check the
5th and reverse gear locking unit and renew if necessary
⇒ page 97 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

54 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2 Servicing selector mechanism for ve‐

hicles from 05.99 onwards, vehicle
identification number 8D-X-260 001
►
Identification: gear lever can no longer be pressed down when
engaging reverse gear.
Overview
♦ ⇒ „2.1 Exploded view - selector mechanism“, page 55
♦ ⇒ „2.2 Servicing gear lever and push rod (rear)“, page 57
♦ ⇒ „2.3 Servicing selector rod and push rod (front)“,
page 58
♦ ⇒ „2.4 Removing and installing gear lever with push rod (rear)“,
page 59
♦ ⇒ „2.5 Removing and installing selector mechanism from
05.99 onwards“, page 60
♦ ⇒ „2.6 Adjusting selector mechanism fromCopying
Protected by copyright. 05.99foronwards“,
private or commercial purposes, in part or in whole, is not
page 62 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.1 Exploded view - selector mechanism

Note

♦ Lubricate all bearings and moving surfaces.

♦ Select correct type of grease from ⇒ Electronic parts catalogue .

2. Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number 8D-X-260 001 ► 55
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

I - Servicing gear knob, boot,

gear lever and push rod (rear)
⇒ page 57
II - Servicing selector rod and
push rod (front) ⇒ page 58

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

56 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2.2 Servicing gear lever and push rod (rear)

1 - Gear knob
2 - Bush
3 - Gear lever boot
4 - Cover for centre console
❑ Retaining hook on rear
of cover; pry out careful‐
ly from centre console
❑ Removing and installing
⇒ page 59
5 - Bush
6 - Gear lever
❑ Grease area around
bottom bore
❑ Grease ball
7 - Spacer tube
❑ Grease
8 - Nut
❑ 10 Nm
9 - Noise insulation
10 - Circlip
❑ Take out before remov‐
ing ball stop
11 - Washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
12 - Rubber ring with respect to the correctness of information in this document. Copyright by AUDI AG.

13 - Ball socket
14 - Rubber ring
15 - Push rod (rear)
❑ With ball housing
16 - Bolt
❑ 6 Nm
❑ 4x
❑ For push rod (rear) to selector housing

2. Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number 8D-X-260 001 ► 57
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2.3 Servicing selector rod and push rod (front)

1 - Push rod (rear)

❑ With ball housing
2 - Bolt
❑ 6 Nm
❑ 4x
❑ Push rod (rear) to selec‐
tor housing
3 - Hexagon socket head bolt
❑ 25 Nm
4 - Washer
5 - Hexagon socket head bolt
❑ 25 Nm
6 - Clamp
7 - Nut
❑ 10 Nm
❑ 4x
❑ Secures selector hous‐
ing to body
8 - Nut
❑ 10 Nm
❑ Secures selector fork
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Self-locking permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always renew with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Gear lever
10 - Spacer tube
❑ Grease
11 - Selector fork
12 - Bolt
❑ Secures selector fork
13 - Selector housing
14 - Tensioning ring
15 - Boot
❑ Remove catalytic converter and front heat shield before removing and installing

Note

♦ Carefully pull bellows over selec‐

tor rod
♦ Align bellows with markings on
selector rod and push rod

16 - Selector rod
❑ With selector joint
17 - Bolt
❑ 23 Nm
❑ Self-locking

58 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

❑ Always renew
18 - Hexagon socket head bolt
❑ 40 Nm
❑ Cannot be removed from push rod (front) bearing bush
19 - Push rod (front)
❑ With bearing bush, bolt and washers

2.4 Removing and installing gear lever with

push rod (rear)
Removing
– Unscrew gear knob from gear lever.

Note

The gear lever boot is removed together with the cover for the
centre console.

– Lift off cover for centre console slightly -arrows A-.

– Pull cover slightly towards the rear -arrow B- and then lift off
complete cover.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew noise insulation for selector housing -arrows-.

2. Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number 8D-X-260 001 ► 59
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Remove nuts -1- for selector housing.

This lowers the selector housing.
– Unscrew hexagon socket head bolt -2- and detach push rod.
– Unscrew hexagon socket head bolt -3- and detach selector
rod.
– Then detach entire push rod (rear) from selector housing
-arrows-.
– Remove gear lever with push rod (rear) from selector housing.
Installing
Installation is carried out in reverse sequence; note the following:
– Adjust selector mechanism ⇒ page 62 .
Tightening torques
Component Nm
Push rod (rear) to selector housing 6
Selector rod to selector fork/gear lever 25
Push rod (front) to push rod (rear) 25
Selector housing to body 10
Noise insulation for selector housing to push rod 10
(rear)

2.5 Removing and installing selector mech‐

anism from 05.99 onwards
Removing
– Unscrew gear knob from gear lever.

Note

The gear lever boot is removed together with the cover for the
centre console.

– Lift off cover for centre console slightly -arrows A-.

– Pull cover slightly towards the rear -arrow B- and then lift off
complete cover.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

60 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Unscrew noise insulation for selector housing -arrows-.

– Unscrew nuts for selector housing -arrows-.

– Remove rear section of exhaust system (rearward of clamp(s))
and, if necessary, front exhaust pipe with catalytic converter
⇒ Engine, mechanics; Rep. gr. 26 .

– Remove selector rod -arrow A-.

– Unscrew hexagon socket head bolt on push rod -arrow B-.
– Remove heat shield (front) above exhaust system.
– Pivot selector housing with selector rod and push rod down‐
wards and
Protected remove.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation is carried out in reverse sequence; note the following:

– Push selector rod on so that the new securing bolt fits in the
recess in the selector shaft.

– Then secure selector rod -arrow A-.

– Then bolt push rod to gearbox -arrow B-.
– Install exhaust system so it is free of stress ⇒ Engine, me‐
chanics; Rep. gr. 26 .
– Adjust selector mechanism ⇒ page 62 .
Tightening torques
Component Nm
Noise insulation for selector housing to push rod 10
(rear)
Selector housing to body 10
Push rod to gearbox 40
Selector rod to gearbox 23 1)
• 1) Renew bolt.

2. Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number 8D-X-260 001 ► 61
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2.6 Adjusting selector mechanism from

05.99 onwards
The following are prerequisites for correct gear lever alignment:
• Gear selector linkage must be in proper condition and undam‐
aged.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
– Unscrew gear knob from gear lever.

Note

The gear lever boot is removed together with the cover for the
centre console.

– Lift off cover for centre console slightly -arrows A-.

– Pull cover slightly towards the rear -arrow B- and then lift off
complete cover.

– Unscrew noise insulation for selector housing -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

62 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Measure distance between body and rear push rod (in selector
mechanism).
♦ Specification: distance -a- = 41 mm
– If distance measured is not correct, adjust dimension -a- as
follows:
– Loosen bolt -arrow- for push rod.
♦ Rear push rod (in selector mechanism) should move freely in
both directions on slide.
– Set to distance -a- by moving rear push rod (in selector mech‐
anism).
– Tighten bolt for push rod -arrow- to 25 Nm.

– Loosen bolt for selector rod -arrow B-.

♦ Connection between selector rod and selector mechanism
should move freely.

Adjust gear lever as follows:

♦ Gear lever is vertical in direction of travel.
♦ Gear lever inclined slightly to the rear (angle -a- approx. 5°).

Note

The illustration shows the gear lever from the right.

– Hold gear lever in this position.

– Tighten bolt for selector rod to 25 Nm.

Note

The gear lever must Protected

remain in the same position while the bolt is
by copyright. Copying for private or commercial purposes, in part or in whole, is not

being tightened.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.7 Checking gear lever adjustment

• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Depress clutch.
– Select all gears several times. Pay particular attention to the
operation of the reverse gear locking mechanism.
• The gear lever should return by itself from the 5th/reverse gear
gate into the 3rd/4th gear gate.
• It should only be possible to engage reverse gear after moving
the gear lever into the 3rd/4th gate in neutral.

2. Servicing selector mechanism for vehicles from 05.99 onwards, vehicle identification number 8D-X-260 001 ► 63
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

• It should not be possible to select reverse gear directly from

5th gear.

Note

If it is possible to select reverse gear directly from 5th gear, or if

only 5th gear and reverse cannot be engaged, the locking unit for
5th and reverse gear should be checked and if necessary re‐
newed ⇒ page 97 .

– Fit boot and gear knob.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

64 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3 Removing and installing gearbox

Special tools and workshop

equipment required
♦ Gearbox support -3282-
♦ Adjustment plate -3282/10-
♦ Torque wrench -
V.A.G
Protected 1331-
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦withTorque wrench
respect to the - of information in this document. Copyright by AUDI AG.
correctness
V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-

♦ Set of open ring spanners for lambda probe -3337-

3. Removing and installing gearbox 65

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3.1 Removing gearbox

Note

All cable ties which are released or cut open during removal must
be fitted in the same position when installing.

Caution

♦ Follow steps required when disconnecting battery ⇒ Elec‐

trical system; Rep. gr. 27 .

– Obtain radio code on vehicles with coded radio.

– With the ignition switched off, disconnect battery earth strap.
Vehicles with 4-cylinder normally aspirated engine:
– Unplug connectors -2- and -3- at air mass meter and
ACF valve.
– Pull ACF valve -1- off air cleaner housing.
– Remove O-type clips from air duct -4-.
– Remove air cleaner housing -arrow-; air duct -4- remains in‐
stalled.
– Remove nuts for exhaust manifold/front exhaust pipe ⇒ En‐
gine, mechanics; Rep. gr. 26 .

Note

Flexible element in front exhaust pipe must not be bent more than
10° - otherwise it can be damaged.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Vehicles with 4-cylinder turbo engine: with respect to the correctness of information in this document. Copyright by AUDI AG.

– Disconnect wires/connectors:
1 - At solenoid valve for charge pressure control -N75-
2 - At ACF valve
3 - At output stage -N122-
4 - At air mass meter
– Disconnect hoses and remove air cleaner housing -arrows-.
– Unbolt coolant expansion tank and move it to one side.

66 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Unplug connector for lambda probe -arrow- and move wiring

clear.
– Remove nuts for turbocharger/front exhaust pipe ⇒ Engine,
mechanics; Rep. gr. 26 .

Note

Flexible element in front exhaust pipe must not be bent more than
10° - otherwise it can be damaged.

Vehicles with 6-cylinder engine:

– Remove intake hose -A- -arrows-.

– Unbolt coolant expansion tank -B- -arrows- and place to one
side.
– Detach Lambda probes from exhaust pipes (left and right) us‐
ing Lambda probe open ring spanner set -3337- and move
clear to the side.
All vehicles:
– Unscrew engine/gearbox securing bolts accessible from
above.

– Remove noise insulation -arrows-.

– Unbolt bracket for noise insulation -arrow-.

Vehicles with 4-cylinder engine:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach heat shields -arrow 1- and -arrow 2- above right-hand

drive shaft.

3. Removing and installing gearbox 67

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Unbolt right-hand gearbox support complete with bonded rub‐

ber mounting -arrows-
– Release clamps on exhaust system and push them towards
catalytic converter.
– Pull catalytic converter out downwards together with exhaust
pipe.
Vehicles with 6-cylinder engine:
– Detach heat shield above left and right drive shafts.

– Unbolt front exhaust pipes with catalytic converters (left and

right) from exhaust manifold -arrows- (3 nuts on each side) ⇒
Engine, mechanics; Rep. gr. 26 .

– Remove engine speed sender -G28- on left of gearbox

-arrow- and move clear.
All vehicles:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach drive shafts from permitted
flange unless
shafts and place
authorised by AUDIthem
AG. AUDIonAG does not guarantee or accept any liability
transverse links. with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Make sure you do not damage surface coating on drive shafts.

– Unplug connector from speedometer sender -G22- -arrow A-.

– Unplug connector from reversing light switch -F4- (multi-func‐
tion sender) -arrow B-.
– Disconnect all other electrical connections and earth wires
from gearbox and from engine/gearbox securing bolts.

68 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Detach starter from engine/gearbox and secure if necessary

⇒ Electrical system; Rep. gr. 27 .

Note

Starter cables do not need to be disconnected.

Vehicles with standard-travel selector mechanism:

– Remove bolt -2- at selector joint -1- on selector rod.

Vehicles with short-travel selector mechanism and selector
mechanism from 05.99 onwards:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Remove selector rod -arrow A-.

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew hexagon socket head bolt on push rod -arrow B-.

All versions:

– Unscrew bottom engine/gearbox securing bolts, except for

bolts indicated by arrows -A- and -B-.

3. Removing and installing gearbox 69

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Set up gearbox support -3282- with adjustment plate

-3282/10- to remove manual gearbox 012, and place gearbox
support on engine and gearbox jack -V.A.G 1383 A- .
A - Support elements

Note

♦ The support elements are shown in schematic form -A-, arrow

-B- points in the direction of travel.
♦ Adjustment plate -3282/10- can only be fitted in one correct
position.

– Place engine and gearbox jack -V.A.G 1383 A- with gearbox

support -3282- underneath gearbox and support gearbox.

Note

If gearbox support -3282- is not available, gearbox can be re‐

moved and installed using engine and gearbox jack -V.A.G 1383
A- and universal support -V.A.G 1359/2- .

– Align adjustment plate -3282/10- parallel to gearbox and lock

safety support -arrow- on gearbox.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Vehicles with 4-cylinder engine:

– Unbolt gearbox support (left-side) from bonded rubber mount‐
ing. -2-.

70 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Vehicles with 6-cylinder engine:

– Unbolt gearbox supports on both sides complete with bonded
rubber mountings from gearbox and subframe -1- and -2-.

All versions:
– Remove remaining engine/gearbox securing bolts -arrow A-
and -arrow B-.
– Press gearbox off dowel sleeves and lower carefully with en‐
gine and gearbox jack -V.A.G 1383 A- just far enough to gain
access to the clutch slave cylinder.

Note

When lowering gearbox, take care not to damage pipe/hose as‐

sembly for clutch slave cylinder.

– Detach clutch slave cylinder from gearbox -arrow- and secure

with wire; do not open pipe/hose system.

Caution

Do not depress clutch pedal after removing slave cylinder. The

slave cylinder would then be destroyed once pedal force ex‐
ceeds approx. 300 N.

– Lower gearbox.

Note

When lowering gearbox, make sure there is sufficient clearance

from drive shafts.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Before
permitted unlesscarrying out
authorised by assembly
AUDI AG. AUDI AG work, secure
does not gearbox
guarantee with
or accept any gear‐
liability
box support -VW 353- or retaining plate -VW 309- to assembly
with respect to the correctness of information in this document. Copyright by AUDI AG.

stand or engine and gearbox support -VAS 6095-

⇒ page 76 .

3.2 Installing gearbox

Installation is carried out in reverse sequence; note the following:

3. Removing and installing gearbox 71

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

WARNING

♦ Bolts and other components coming into direct contact

with the gearbox housing have a surface coating that is
designed to be compatible with either aluminium or mag‐
nesium ⇒ page 12 .
♦ In order to avoid contact corrosion, use only the bolts and
other components listed in the ⇒ Electronic parts Cata‐
logue .

– Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Do not grease the guide sleeve.
• It should be possible to push the clutch plate back and forth
slightly on the input shaft.
– Check clutch release bearing for wear and renew if necessary
⇒ Item 8 (page 34) . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– If plastic ring -arrows- has come loose, service release bearing
with respect to the correctness of information in this document. Copyright by AUDI AG.
as required ⇒ page 35 .

Note

The release bearing must be renewed if the groove worn on the

plastic ring is deeper than 0.8 mm.

– Check that dowel sleeves for centralising engine/gearbox are

in the cylinder block, install if necessary.
– Place intermediate plate on dowel sleeves at engine flange.
– Before installing gearbox, tie electrical wires and brackets off
to one side so that they are not trapped between the engine
and the gearbox.
– Before installing, use a thread tap to clean all remaining lock‐
ing fluid out of tapped holes for bolted connection between
clutch slave cylinder and gearbox and between selector joint
and selector rod.
– Renew all self-locking nuts.

72 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Lightly lubricate surface where plunger and clutch release lev‐

er make contact -arrow B- using copper grease (commercially
available).
– Raise gearbox far enough to be able to install clutch slave cyl‐
inder with bracket for pipe/hose assembly.
– Guide slave cylinder -1- into opening in gearbox housing,
keeping it as straight as possible (without tilting plunger
-arrow A-) and insert in recess -arrow B- on clutch release
lever -3-.

Note

If the slave cylinder -1- is inserted at an angle, there is a danger

that the plunger -arrow A- will be guided past the clutch release
lever -3-.

– Secure slave cylinder with new bolt -2-. Tightening torque

⇒ Item 2 (page 33)
– When aligning the gearbox with the engine, turn crankshaft
back and forth slightly to make it easier to insert the gearbox
input shaft splines into the clutch plate.

Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Press the clutch pedal carefully after installing the gear‐
box.
♦ If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down
further.
♦ The plunger of the slave cylinder is likely to have been
guided past the clutch release lever.
♦ The slave cylinder would then be destroyed once pedal
force exceeds approx. 300 N.
♦ For comparison: normal pedal force is approx. 115 N.

– Install engine/gearbox securing bolts -arrow A- and

-arrow B-.
– Install starter ⇒ Electrical system; Rep. gr. 27 .
– Tighten top bolts securing engine to gearbox to specified tor‐
que ⇒ page 74 .
– Push selector rod on so that the new securing bolt fits in the
recess in the selector shaft.

3. Removing and installing gearbox 73

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Then secure selector rod -arrow A-.

– Then bolt push rod to gearbox -arrow B-.
– If previously removed, install gearbox supports with bonded
rubber mountings. Tightening torque ⇒ page 74
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Install exhaust system so it is free of stress ⇒ Engine, me‐
chanics; Rep. gr. 26 .
– Check selector mechanism setting and adjust if necessary.
♦ ⇒ „1.3 Adjusting standard-travel selector mechanism“,
page 45
♦ ⇒ „1.6 Adjusting short-travel selector mechanism“, page 51
♦ ⇒ „2.6 Adjusting selector mechanism from 05.99 onwards“,
page 62
– Check gear oil level in gearbox ⇒ page 78 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. gr. 27 .
Tightening torques

Note

♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine or gear oil may be used,
but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques is ± 15 %.

Engine (4-cylinder) to gearbox

Item Bolt Nm
1, 3, 4 M12 x 67 65
2, 6 Protected by M12 x 90
copyright. 65 purposes, in part or in whole, is not
Copying for private or commercial
5, 11 M12 x 110 65
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7 … 10 M10 x 45 45
A Dowel sleeves for centralising

Engine/gearbox assembly mountings (4-cylinder)

Item Bolt Qty. Nm
1 M10 x 30 3 40
2 M10 x 35 1 50
3 M8 x 20 2 23

74 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Engine (6-cylinder) to gearbox

Item Bolt Qty. Nm
1 M12 x 67 3 65
2 M12 x 90 1 65
3 M12 x 80 1 65
4 M10 x 45 3 45
5 M10 x 135 1 45
5 1) M12 x 130 1 65
A Dowel sleeves for centralising
• 1 Top starter bolt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Engine/gearbox assembly mountings (6-cylinder)with respect to the correctness of information in this document. Copyright by AUDI AG.

Item Bolt Qty. Nm

1 M10 x 35 3 40
2 M8 x 20 2 23

Component Nm
Engine speed sender -G28- 10
Heat shields above drive shafts to gearbox 23
Selector rod/selector joint to gearbox 1) 23
Push rod to gearbox 40
Catalytic converter to mounting lugs 25
Front exhaust pipe to turbocharger/exhaust mani‐ 25
fold
Clamp for exhaust pipe 40
Bracket for noise insulation to subframe 10
• 1) Renew bolt

3.3 Transporting gearbox

Special tools and workshop equipment required
♦ Lifting aid -T40013-

The lifting aid -3282- can be used to transport the gearbox and
also when setting up the gearbox on gearbox support -T40013- .

3. Removing and installing gearbox 75

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Insert lifting aid -T40013- in drillings on gearbox housing

-arow A- and secure.
– Push together adjusting mechanism of lifting aid as far as stop.
– Engage hook of workshop hoist in 2nd notch -arrow B- on lift‐
ing aid .
– Lift gearbox with workshop hoist and lifting aid .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ Gearbox can also be transported using gearbox lifting tackle

-3336- (bolt onto clutch housing),
♦ Set support arm on sliding bracket by means of locking pin
-arrow-. Number of holes visible = 17.

3.4 Securing gearbox to assembly stand

Special tools and workshop equipment required
♦ Support plate -VW 309-

76 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Gearbox support -VW 353-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– To carry out repairs, secure gearbox to assembly stand or en‐

gine and gearbox support -VAS 6095- with gearbox support -
VW 353- and support plate -VW 309- .

3. Removing and installing gearbox 77

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

4 Checking oil level in manual gearbox

Special tools and workshop equipment required
♦ Multi-point bit -3357-

Note

♦ The vehicle must be horizontal when checking gear oil level.

An inspection pit or a 4-post lifting platform is ideal.
♦ The oil filler plug is on the left of the gearbox below the speed‐
ometer sender; it may be concealed by the heat shield for the
drive shaft.
♦ Use either multi-point bit -3357- or Allen key (17 mm) (accord‐
ing to plug version) to loosen gear oil filler plug.

– To check oil level, unscrew oil filler plug -arrow-.

– Check oil level with a suitable tool (such as a length of wire
bent to shape).
♦ Specification: oil level 7 mm below bottom lip of oil filler hole.

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The oil can be filled up to the bottom lip of the oil filler hole when
servicing.

– Top up with gear oil if necessary. Specifications ⇒ Electronic

parts catalogue .

– Screw in oil filler plug.

Tightening torque
Component Nm
Oil filler plug 25
The plug has a coating which is matched to the material of the
gearbox housing: aluminium or magnesium ⇒ page 2 .
Select correct plug from ⇒ Electronic parts catalogue .

78 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

5 Dismantling and assembling gearbox

Overview
♦ ⇒ „5.1 General layout of gearbox“, page 79
♦ ⇒ „5.2 Exploded view - dismantling and assembling gearbox“,
page 80
♦ ⇒ „5.3 Exploded view - removing and installing input shaft ball
bearing and multi-function sender“, page 81
♦ ⇒ „5.4 Exploded view - removing and installing input shaft,
pinion shaft, selector rods and gearbox cover“, page 83
♦ ⇒ „5.5 Assembly sequence - dismantling and assembling
gearbox“, page 85

5.1 General layout of gearbox

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Reverse gear
❑ Removing and installing
reverse gear wheel
⇒ page 128
7 - Gearbox housing
8 - Gearbox cover
9 - Input shaft
❑ Dismantling and assem‐
bling ⇒ page 99
10 - Pinion shaft
❑ Dismantling and assem‐
bling ⇒ page 113
11 - Ball bearing
❑ Adjusting
⇒ „1.3 Adjusting input
shaft“, page 110
12 - Differential
❑ Removing and installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 137 with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Dismantling and assem‐
bling ⇒ page 141
13 - Large tapered roller bear‐
ing
❑ For pinion shaft
❑ Adjusting
⇒ „4.5 Adjusting pinion shaft“, page 153
14 - Small tapered roller bearing
❑ For pinion shaft
❑ Adjusting ⇒ „4.5 Adjusting pinion shaft“, page 153

5. Dismantling and assembling gearbox 79

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

5.2 Exploded view - dismantling and assembling gearbox

I - Exploded view - removing

and installing input shaft ball
bearing and multi-function
sender ⇒ page 81
II - Exploded view - removing
and installing input shaft, pin‐
ion shaft, selector rods, gear‐
box cover ⇒ page 83

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

80 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

5.3 Exploded view - removing and installing input shaft ball bearing and multi-
function sender

1 - Gearbox housing
❑ Housing manufactured
from aluminium or mag‐
nesium
⇒ Item 14 (page 84)
❑ With differential and
flange shafts
❑ Removing and installing
flange shafts
⇒ page 129
❑ Removing and installing
differential ⇒ page 137
❑ Removing and installing
speedometer sender
and drive wheel
⇒ page 134
❑ Installation position of
breather ⇒ page 82
❑ Breather made of differ‐
ent materials for alumi‐
nium and magnesium
gearboxes
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
2 - Torx socket head bolt
❑ Self-locking Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Black: only for alumini‐

um gearboxes
❑ Bright metal: for alumi‐
nium and magnesium
gearboxes
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
❑ Tighten to 35 Nm on aluminium gearboxes
❑ Tighten to 25 Nm on magnesium gearboxes
3 - Guide sleeve
❑ With O-ring and oil seal for input shaft ⇒ page 33
❑ Installation position: Oil drain hole points downwards (if provided)
❑ Guide sleeve is made of different materials for aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
4 - Dished spring
❑ Smaller diameter (convex side) faces guide sleeve
5 - Circlip
❑ Determining thickness ⇒ „1.3 Adjusting input shaft“, page 110
6 - Ball bearing
❑ Removing and installing ⇒ page 85
7 - Circlip
❑ Determining thickness ⇒ „1.3 Adjusting input shaft“, page 110

5. Dismantling and assembling gearbox 81

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

8 - Input shaft
❑ Removing and installing ⇒ page 85
❑ Dismantling and assembling ⇒ page 99
❑ Adjusting ⇒ page 110
❑ Servicing bearings for input shaft ⇒ page 99
9 - Bolt
❑ Black: only for aluminium gearboxes
❑ Bright metal: for aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Tighten to 25 Nm on aluminium gearboxes
❑ Tighten to 15 Nm on magnesium gearboxes Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Locking plate with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ For multi-function sender

❑ Locking plate made of different material for aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
11 - Multi-function sender
12 - Connector for multi-function sender
13 - Bolt
❑ 10 Nm
❑ Black: only for aluminium gearboxes
❑ Bright metal: for aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
14 - Selector shaft cover
❑ Removing and installing ⇒ page 93
15 - Locking unit for 5th gear and reverse gear
❑ Removing and installing ⇒ page 97

Installation position of breather

After pressing in, the breather must project 21 mm out of the
housing.

82 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

5.4 Exploded view - removing and installing input shaft, pinion shaft, selector
rods and gearbox cover

1 - Selector rod with selector

fork for 3rd and 4th gear
❑ Dismantling and assem‐
bling ⇒ page 93
❑ Renewing bearing
bushes ⇒ page 93
2 - Input shaft
❑ Dismantling and assem‐
bling ⇒ page 99
❑ Adjusting ⇒ page 110
❑ Servicing bearings for
input shaft ⇒ page 110
3 - Stop bolt (left-side)
❑ 40 Nm
❑ The stop bolts are made
of different materials for
aluminium and magne‐
sium gearboxes
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
4 - Seal
5 - Relay shaft
❑ Installation position
⇒ page 93
6 - Seal
7 - Stop bolt (right-side)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 40 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ The stop bolts are made

of different materials for
aluminium and magne‐
sium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue
8 - Selector shaft
❑ Installation position ⇒ page 93
❑ Renewing oil seal for selector shaft ⇒ page 93
9 - Detent segment
❑ Installation position ⇒ page 93
10 - TORX bolt
❑ 25 Nm
❑ With collar to secure detent segment spring
11 - Selector rod with 1st/2nd/5th and reverse gear selector forks
❑ Dismantling and assembling ⇒ page 93
❑ Removing and installing ball sleeves ⇒ page 96
12 - Pinion shaft
❑ Dismantling and assembling ⇒ page 113
❑ Adjusting ⇒ page 153
❑ Servicing bearings for pinion shaft ⇒ page 113

5. Dismantling and assembling gearbox 83

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

13 - Gearbox cover
❑ Aluminium version must only be fitted to an aluminium gearbox housing
❑ Magnesium version must only be fitted to a magnesium gearbox housing
❑ Note identification markings ⇒ page 84
❑ Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-
❑ Removing and installing oil collector ⇒ page 84
14 - Gearbox housing
❑ Aluminium version must only be fitted to an aluminium gearbox cover
❑ Magnesium version must only be fitted to a magnesium gearbox cover
❑ Note identification markings ⇒ page 84
❑ Select correct version according to gearbox code letters ⇒ Electronic parts catalogue ⇒ page 2
15 - TORX bolt
❑ 22 Nm
❑ On aluminium version: black, M8 x 48, without washer
❑ For magnesium gearboxes from approx. 09.97 onwards: bright metal, M8 x 51, fit washer with each bolt
❑ On magnesium version: different bolt lengths ⇒ page 85
❑ Renew

Removing and installing oil collector

Removing
– Turn oil collector -arrow- and then pull out.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Installing
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Push oil collector into gearbox cover until it snaps into place.
♦ Installation position: oil collector faces upwards in gearbox
cover.

Gearbox cover and gearbox housing markings

The identification marking »Mg Al 9 Zn 1« can be found near
-arrow 1- and -arrow 2- on gearboxes with a magnesium housing.
Mg = Magnesium; additional data is only for production.
The gearbox code letters also indicate whether a gearbox has a
magnesium housing ⇒ page 2 .

84 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Locations of bolts for gearbox cover on gearboxes with magne‐

sium housing from approx. 09.97 onwards
1- Bright metal bolts, M8 x 48, without washer
2- Bright metal bolts, M8 x 51, with captive washer

Note

Only M8 x 51 bolts with captive washers are supplied as replace‐

ment parts; if necessary these can be used for all bolted connec‐
tions on the gearbox cover.

5.5 Assembly sequence - dismantling and

assembling gearbox
Removing and installing input shaft ball bearing, multi-function
sender, input shaft, pinion shaft, selector rods and gearbox cover

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Dismantling and assembling gearbox 85

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
♦ Fitting tool -3235- or fitting
tool -T10246-
♦ Multi-point bit -3357-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/2-

♦ Drip tray , e.g. -VAS 6208-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Sealing paste -AMV 188 001 02-

86 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ The differential does not have to be removed in order to re‐

move the above-mentioned components.
♦ Removal is only necessary when adjustment work has to be
carried out ⇒ „4.3 Table of adjustments“, page 152 .

Dismantling gearbox
– Place drip tray e.g. -VAS 6208- under the gearbox.
– Use multi-point bit -3357- to remove drain plug and drain gear
oil.
– Secure gearbox to assembly stand or engine/gearbox support
-VAS 6095- .

– Remove clutch release lever -A- together with release bearing.

Note

♦ Before pulling off guide sleeve -B-, cover splines on input shaft
with a shrink-fit hose to protect oil seal.
♦ Removing oil seal in guide sleeve ⇒ Item 6 (page 33)

– Remove guide sleeve -B-

– Remove dished spring -C-
– Remove circlip -D- in front of input shaft ball bearing.
– If the ball bearing, input shaft or gearbox housing is not to be
replaced, note the thickness of the circlip.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull the ball bearing for input shaft out of gearbox housing.

5. Dismantling and assembling gearbox 87

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Remove the circlip -arrow- behind the ball bearing for input
shaft.
– If the ball bearing, input shaft or gearbox housing is not to be
replaced, note the thickness of the circlip.

– Unbolt gearbox cover -A- from gearbox housing -B-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove bolts -arrows- and pull out multi-function sender.

– Remove relay shaft bolts -arrows-.

88 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Unscrew detent segment -arrow- and swing it out.

– The input shaft -A-, the pinion shaft-B-, the relay shaft -C-, the
selector rods-D- with selector shaft and the selector forks-E-
must be carefully pulled out together.
Assembling gearbox

Note

If the input shaft ball bearing, the input shaft or the gearbox hous‐
ing have been replaced, it is necessary to re-determine the thick‐
ness of the circlips for the input shaft before installing the
components ⇒ „1.3 Adjusting input shaft“, page 110 .

– Swing the gearbox housing into the position shown. The com‐
ponents listed below can then be fitted more easily.

– Assemble the input shaft -A-, the pinion shaft-B-, the relay
shaft -C-, the selector rods -D- with selector shaft and selector
forks -E- together.
– Install these components together into the gearbox housing.

Note

If necessary, the relay shaft -C- and the selector shaft can also
be fitted later ⇒ page 90 and ⇒ page 90 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Dismantling and assembling gearbox 89

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Location of selector mechanism in gearbox.

1- Selector fork for 5th gear and reverse gear
2- Selector fork for 3rd gear and 4th gear
3- Selector fork for 1st gear and 2nd gear
4- Relay shaft
5- Detent segment
6- Selector shaft

Note

Shown in illustration with input shaft and pinion shaft removed.

– Pivot gearbox housing and engage 3rd gear in direction of

-arrow-
.

– Now install relay shaft -A-.

– Insert selector shaft -B- sideways onto drilling in gearbox
housing and fit into mounting eye.
– Then pivot selector shaft carefully into position in direction of
-arrow-.

– Then fit detent segment and secure -arrow-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

90 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Fit relay shaft bolts -arrows-.

– Renew O-ring for multi-function sender.

– Carefully insert multi-function sender and secure -arrows-.

Check whether the dowel sleeves for the gearbox cover -A- are
fitted in gearbox housing -B-.
– Coat sealing surfaces lightly with sealing paste -AMV 188 001
02- .
– Fit gearbox cover onto gearbox housing and secure.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fitpermitted
rear circlip -arrow-
unless authorised by for
AUDIinput shaft
AG. AUDI ballnotbearing.
AG does guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Slide ball bearing onto input shaft.
♦ Position: closed side of ball cage faces towards gearbox hous‐
ing.

5. Dismantling and assembling gearbox 91

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Pressing in ball bearing:

– Slide thrust piece -A- of fitting tool onto input shaft.
– Position fitting tool behind splines for clutch plate.
– Screw in bolts -B- until they make contact.
• The bolts locate in the recess in the thrust plate -A-.

Note

Fitting tool -3235- can also be used if fitting tool -T10246- is not
available.

– Press in ball bearing onto its seat by alternately tightening the

bolts (1/2 turn at a time).

– Now fit front circlip -D- for input shaft ball bearing.
– Then fit dished spring -C-.
♦ Position: convex side towards guide sleeve -B-.

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Before fitting guide sleeve, cover input shaft splines with a
with respect to the correctness of information in this document. Copyright by AUDI AG.

shrink-fit hose to protect oil seal.

♦ Installing oil seal in guide sleeve ⇒ Item 6 (page 33)

– Fit guide sleeve -B- for release bearing with new O-ring
⇒ page 33 .
– Remove shrink hose.
– Fit clutch release lever -A- and release bearing ⇒ page 33 .

92 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

6 Dismantling and assembling selector mechanism in gearbox

Special tools and workshop

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Thrust plate -VW 401-
♦ Tube -VW 420-
♦ Tube -VW 423-
♦ Spacer sleeve -VW 472/2-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Multi-purpose tool -VW 771-

6. Dismantling and assembling selector mechanism in gearbox 93

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ -1- Kukko internal puller 21/4

Note

Installation position of complete selector mechanism in gearbox ⇒ page 97 .

1 - Locking unit for 5th gear

and reverse gear
❑ Removing and installing
⇒ page 97
2 - TORX bolt
❑ 10 Nm
❑ Black: only for alumini‐
um gearboxes
❑ Bright metal: for alumi‐
nium and magnesium
gearboxes
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
3 - O-ring
❑ Always renew
4 - Stop bolt (right-side)
❑ 40 Nm
❑ The stop bolts are made
of different materials for
aluminium and magne‐
sium gearboxes
❑ For correct version, re‐
fer to ⇒ Electronic parts Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
catalogue permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Seal
6 - Relay shaft
7 - Seal
8 - Stop bolt (left-side)
❑ 40 Nm
❑ The stop bolts are made
of different materials for
aluminium and magnesium gearboxes
❑ For correct version, refer to ⇒ Electronic parts catalogue

94 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

9 - Detent segment
10 - TORX bolt
❑ 25 Nm
11 - Spring pin
12 - Selector fork for 5th gear and reverse gear
❑ Installation position ⇒ page 95
13 - Selector rods for 1st/2nd and 5th/reverse gear
14 - Ball sleeve
❑ Removing and installing ⇒ page 96
15 - Selector fork for 1st and 2nd gear
16 - Actuating arm
❑ Installation position ⇒ page 95
17 - Bearing bush for 3rd and 4th gear
❑ Pulling out ⇒ page 96
❑ Driving in ⇒ page 96
18 - Ball sleeve
❑ Lever off the selector rod with a screwdriver
❑ Press onto the selector rod
19 - Selector rod for 3rd and 4th gear
20 - Selector fork for 3rd and 4th gear
21 - Spring pin
22 - Cover
❑ For selector shaft
23 - TORX bolt
❑ 20 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
24 - Selector shaft with respect to the correctness of information in this document. Copyright by AUDI AG.

25 - Oil seal for selector shaft

❑ Lever out with screwdriver
❑ Use tube -VW 420- to insert
❑ Installation position ⇒ page 96

Installation position of selector fork for 5th and reverse gear and
follower for selector rod
♦ Dimension -a- = 55 mm
♦ Dimension -b- = 60 mm

6. Dismantling and assembling selector mechanism in gearbox 95

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Removing and installing ball sleeve

Pulling out bearing bush for 3rd and 4th gear selector rod
A - Internal puller 23.5 ... 30 mm , e.g. -Kukko 21/4- together with
multi-purpose tool -VW 771-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Driving in bearing bush for 3rd and 4th gear selector rod onto stop

Installation position of oil seal

– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Lightly oil outer circumference of oil seal.
– Use tube -VW 420- to insert oil seal.
♦ Dimension -a- = 1 mm

96 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installation position of complete selector mechanism in gearbox:

1- Selector fork for 5th gear and reverse gear
2- Selector fork for 3rd gear and 4th gear
3- Selector fork for 1st gear and 2nd gear
4- Relay shaft
5- Detent segment
6- Selector shaft

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

6.1 Checking and renewing locking unit for

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5th gear and reverse gear

Removing
– Remove heat shield -arrow 2- above drive shaft (right-side).
– Detach heat shield -arrow 1- above drive shaft (right-side) and
pivot downwards.

– Remove locking unit -arrow-.

Assembling locking unit:

– Insert spring -1- into housing -2- and, while exerting light pres‐
sure, turn spring to the left until it locates in the base of the
housing.
– Insert bush -3- onto the spring so that the bent end of the
spring locates in the groove.
– Push bush -3- against spring and turn approx. one turn to the
left, until the lug on the bush aligns with the groove in the
housing -2-.
– Press lug on bush -3- onto stop in the groove in the housing
-2-.
– Turn bush -3- to right and release.
♦ The bush -3- will spring into installation position

6. Dismantling and assembling selector mechanism in gearbox 97

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installation position of bush:

– The lug -arrow A- on the bush must always be opposite the
groove in the housing -arrow B-.
Checking installation position:
– Turn bush to left and release.
• The bush should spring back into position; the lug must be
against the stop (direction indicated by -arrow A-).

Installation position of complete locking unit in gearbox:

The recess -arrow A- faces bolt -arrow B-.
Perform remaining installation operations in reverse order of re‐
moval.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

98 Rep. gr.34 - Controls, housing

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

35 – Gears, shafts
1 Dismantling and assembling input
shaft
Overview
♦ ⇒ „1.1 Exploded view - input shaft“, page 99
♦ ⇒ „1.2 Dismantling and assembling input shaft, renewing roller
bearing/needle bearing for input shaft“, page 102
♦ ⇒ „1.3 Adjusting input shaft“, page 110

1.1 Exploded view - input shaft

Note

♦ When installing new gear wheels or input shaft, consult technical data ⇒ page 2 .
♦ Before installing, heat gear wheels and synchro-hubs to approx. 100 °C (max.) using inductive heater -VAS
6414- (wear protective gloves).
♦ The position of the ball bearing is affected when the ball bearing, gearbox housing or input shaft is renewed.
In this case the input shaft must be re-adjusted ⇒ page 110 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Dismantling and assembling input shaft 99

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Circlip
❑ Mark
❑ Installation position
⇒ page 108
❑ Determining thickness
⇒ „1.3 Adjusting input
shaft“, page 110
2 - Ball bearing
❑ Removing and installing
⇒ page 85
3 - Circlip
❑ Mark
❑ Installation position
⇒ page 108
❑ Determining thickness
⇒ „1.3 Adjusting input
shaft“, page 110
4 - Gearbox housing
❑ Housing manufactured
from aluminium or mag‐
nesium
⇒ Item 14 (page 84)
5 - Needle bearing
❑ Secured with bolt on
some gearboxes
⇒ page 105
❑ Driving out ⇒ page 105
❑ Selecting correct needle
bearing for input shaft
⇒ page 105
❑ Installation position
⇒ page 106
❑ Pressing in
⇒ page 106
❑ Securing ⇒ page 106
6 - Input shaft
❑ With oil feed sleeve
❑ Knocking in oil feed sleeve ⇒ page 106
❑ Adjusting ⇒ page 110
❑ Selecting correct needle bearing for input shaft ⇒ page 105
7 - Needle bearing
❑ For 3rd gear
❑ Mark
8 - 3rd speed selector gear
9 - Spring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Insert in 3rd speed
permitted selector
unless authorisedgear ⇒AG.
by AUDI pageAUDI108
AG does not guarantee or accept any liability

❑ Allocation to selector gear ⇒ Electronic parts catalogue

with respect to the correctness of information in this document. Copyright by AUDI AG.

10 - Synchro-ring for 3rd gear

❑ Checking for wear ⇒ page 108
11 - Circlip
❑ Mark
❑ Installation position ⇒ page 108

100 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

12 - Synchro-hub for 3rd and 4th gear

❑ Higher shoulder faces towards 3rd gear
❑ Pressing off ⇒ page 108
❑ Pressing on ⇒ page 109
13 - Circlip
❑ Mark
❑ Installation position ⇒ page 108
❑ Redetermine thickness if synchro-hub is replaced ⇒ page 109
14 - Locking collar for 3rd and 4th gear
❑ Installation position ⇒ page 109
15 - Synchro-ring for 4th gear
❑ Checking for wear ⇒ page 108
16 - Spring
❑ Insert in 4th speed selector gear ⇒ page 108
❑ Allocation to selector gear ⇒ Electronic parts catalogue
17 - 4th speed selector gear
18 - Needle bearing
❑ For 4th gear
❑ Mark
19 - 5th gear wheel
❑ Pressing off ⇒ page 107
❑ Pressing on ⇒ page 110
20 - Circlip
❑ Mark
❑ Installation position ⇒ page 108
❑ If the 5th gear wheel is renewed determine thickness of required new circlip ⇒ page 109
21 - Roller bearing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Will be damaged during removal

❑ Pulling out ⇒ page 107
❑ Installation position ⇒ page 107
❑ Driving in ⇒ page 107
22 - Sleeve
❑ Made of plastic
23 - Gearbox cover
❑ Aluminium version must only be fitted to an aluminium gearbox housing
❑ Magnesium version must only be fitted to a magnesium gearbox housing
❑ Note identification markings ⇒ page 84
❑ Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-

1. Dismantling and assembling input shaft 101

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1.2 Dismantling and assembling input shaft, renewing roller bearing/needle

bearing for input shaft

Special tools and workshop

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

102 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Tube -VW 415 A-

♦ Tube -VW 416 B-
♦ Thrust plate -VW 447 i-
♦ Multi-purpose tool -
VW 771-
♦ Drift sleeve -30 - 100-
♦ Thrust plate -40 - 105-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Dismantling and assembling input shaft 103

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Drift -VW 222 A-

♦ Drift -30 - 24-
♦ Extractor -40 - 202-
♦ -1- Internal puller -Kukko
21/4-
♦ -3- Splitter -Kukko 17/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

104 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Inductive heater -
VAS 6414-

♦ Feeler gauge
Removing securing bolt
-arrow- for needle bear‐
ing
– Unscrew securing
bolt -arrow-.

Note

Bolt is not fitted on all

versions.

Driving out needle bearing

Selecting correct needle bearing for input shaft

∅ Input shaft Needle bearing part number
Dimension -a- = 27 mm 012 311 123 D
Dimension -a- = 29 mm 012 311 123

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ To avoid damage resulting from incorrect
permittedassembly, check
unless authorised the
by AUDI AG. AUDI AG does not guarantee or accept any liability
following after renewing the input shaft:
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ It must be possible to guide input shaft into place.

♦ Input shaft must be free of play.

1. Dismantling and assembling input shaft 105

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installation position of needle bearing

Distance -a- from lower edge of straight edge to upper edge of
needle bearing = 39.5 mm

Note

Measure distance from top edge of straight-edge and subtract the

width of the straight-edge from the measured distance.

Pressing in needle bearing

Screwing in securing bolt -arrow-

Note

Bolt is not fitted on all versions.

♦ Aluminium gearbox housing

Tighten to 25 Nm.
♦ Magnesium gearbox housing
Tighten to 20 Nm.

Knocking oil feed sleeve into input shaft

Item ∅ Oil feed sleeve Fitting tool
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A 14 mm Drift -VWunless
permitted 222authorised
A- by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
B 16 mm Drift -30 - 24-
♦ Installation position:
Flanged edge on oil feed sleeve faces towards fitting tool.
♦ Installation depth:
3.5 mm below end of shaft

106 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pulling out roller bearing

A - Internal puller 23.5 ... 30 mm , e.g. -Kukko 21/4-
– Before fitting internal puller the plastic sleeve inside the roller
bearing must be destroyed.

Installation position of roller bearing

♦ Dimension -a- = 216 mm

Driving in roller bearing

Pressing off 5th gear wheel

– Remove circlip before pressing off.
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Dismantling and assembling input shaft 107

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressing off 3rd and 4th gear synchro-hub

– Remove circlip before pressing off.
– Place splitter -A- below 3rd speed selector gear. Press off
synchro-hub with 3rd speed selector gear.
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Inserting spring in selector gear

The bent end of the spring -arrow- must be hookedProtected
into the hole
in the selector gear.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Checking synchro-ring for wear

– Press synchro-ring into locking collar and measure gap -a-
with a feeler gauge at positions -A-, -B- and -C-.
– Add the measured values and divide by 3.
The average gap must not be less than 0.5 mm.

Installation position of circlips

♦ The circlips -1- and -2- secure the input shaft ball bearing.
Determining thickness ⇒ „1.3 Adjusting input shaft“, page 110 .
♦ The circlip -3- secures the 3rd and 4th gear synchro-hub.
Thickness: 2.00 mm. Identification: brown colour.
♦ The circlip -4- secures the 3rd and 4th gear synchro-hub.
Determining thickness ⇒ page 109 . Identification: blue colour.
♦ Circlip -5- secures 5th gear wheel.
Determining thickness ⇒ page 109 .

108 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Determining thickness of circlip

– Determine the thickest circlip that will just fit and install it.
– Determine circlip as accurately as possible from table. For part
number, refer to ⇒ Electronic parts catalogue .
The following circlips are available for 3rd and 4th gear synchro-
hub
Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05
The following circlips are available for 5th gear wheel
Circlip thickness (mm)
1.90unless authorised by AUDI 1.96 2.02
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted AG. AUDI AG does not guarantee or accept any liability
1.93 1.99
with respect to the correctness of information in this document. Copyright by AUDI AG.

Heating synchro-hub for 3rd and 4th gear to approx. 100° C and
pressing on

WARNING

Wear protective gloves.

♦ Installation position:
Higher inside collar faces 3rd gear.

Installation position of locking collar

Different types of locking collar are installed: version -A- with
chamfered surface -arrow 1- or version -B- with large shoulder
-arrow 3-.
♦ Installation position:
Chamfered surface -arrow 1- faces 4th gear.
Small shoulder -arrow 2- faces 3rd gear.
Large shoulder -arrow 3- faces 4th gear.

1. Dismantling and assembling input shaft 109

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Heating 5th gear wheel to approx. 100°C and pressing on

WARNING

Wear protective gloves.

♦ Installation position:
Higher shoulder faces towards reverse gear.

1.3 Adjusting input shaft

(Determining thickness of circlips for input shaft)
Special tools and workshop equipment required
♦ Drift sleeve -30 - 100-

♦ Distance gauge -3167-

♦ Depth gauge Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The input shaft must be readjusted if the gearbox housing, the
with respect to the correctness of information in this document. Copyright by AUDI AG.
input shaft or the ball bearing have been renewed.
– Clamp input shaft in vice using jaw covers -A-.
– Place distance gauge -3167- onto 3rd speed selector gear.
– Place gearbox housing over input shaft and onto distance
gauge .

110 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Apply depth gauge to gearbox housing and measure down to

the lower circlip groove in the input shaft.
♦ Measurement in the following example: -a- = 28.50 mm

– Apply depth gauge to gearbox housing and measure down to

seating surface for ball bearing.
♦ Measurement in the following example: -b- = 26.80 mm
Determining thickness for circlip x behind input shaft ball bearing
Formula: „x“ = distance „a“ – distance „b“
Example:
Dimension „a“ 28.50 mm
- Dimension „b“ 26.80 mm
= Dimension „x“ 1.70 mm
(thickness of circlip)
– Select circlip from table. For part numbers, refer to ⇒ Elec‐
tronic parts catalogue .
Circlips available
Dimension „x“ Thickness (mm)
1.48 … 1.56 1.54
1.57 … 1.65 1.63
1.66 … 1.74 1.72
1.75 … 1.83 1.81
1.84 … 1.92 1.90
1.93 … 2.01 1.99
2.02 … 2.10 2.08
2.11 … 2.20 2.17
2.21 … 2.27 2.25
2.28 … 2.35 2.33
Determining thickness for circlip in front of input shaft ball bearing
– Knock rear circlip (as determined) and ball bearing onto input
shaft using drift sleeve -30-100- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Dismantling and assembling input shaft 111

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Determine the thickest circlip which will still just fit.

– Determine circlip as accurately as possible from table. For part
numbers, refer to ⇒ Electronic parts catalogue .
Circlips available
Circlip thickness (mm)
1.45 1.72 1.99
1.54 1.81 2.08
1.63 1.90 2.17
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

112 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2 Pinion shaft
Overview
♦ ⇒ „2.1 Exploded view - pinion shaft“, page 113
♦ ⇒ „2.2 Dismantling and assembling pinion shaft“, page 116
♦ ⇒ „2.3 Reinforcements from 08.98 onwards (from gearbox
manufacturing date 17 08 8 onwards) in area of 4th gear
wheel“, page 126

2.1 Exploded view - pinion shaft

Note

♦ Refer to technical data ⇒ page 2 when installing new gear wheels or the final drive gear set.
♦ Before installing, heat tapered roller bearing inner races and synchro-hubs to approx. 100 °C (max.) using
inductive heater -VAS 6414- (wear protective gloves).
♦ Adjustment work is required when renewing the parts marked with 1)
⇒ „4.3 Table of adjustments“, page 152 .

1 - Gearbox housing 1)
❑ Housing manufactured
from aluminium or mag‐
nesium
⇒ Item 14 (page 84)
2 - Shim „S3“
❑ Table of adjustments
⇒ page 152
3 - Outer race for large tapered
roller bearing 1)
❑ Pulling out ⇒ page 119
❑ Pressing in
⇒ page 119
4 -Protected
Pinionbyshaft 1)
copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ withIsrespect
mated with crown
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information in this document. Copyright by AUDI AG.
wheel, always renew to‐
gether as a set
❑ Adjusting pinion shaft
and crown wheel
⇒ page 150
❑ Reinforcements on
gearboxes manufac‐
tured from 17 08 8 on‐
wards ⇒ page 126
5 - Inner race for large tapered
roller bearing 1)
❑ Renew
❑ Will be damaged during
removal
❑ Pressing off
⇒ page 121
❑ Pressing on
⇒ page 121

2. Pinion shaft 113

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

6 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
❑ Re-determine thickness if tapered roller bearing is renewed ⇒ page 121
7 - Needle bearing
❑ For 1st gear
8 - 1st speed selector gear
9 - Spring
❑ Insert in 1st speed selector gear ⇒ page 123
❑ Allocation to selector gear ⇒ Electronic parts catalogue
10 - Synchro-ring for 1st gear
❑ Checking for wear ⇒ page 123
11 - Synchro-hub for 1st and 2nd gear
❑ Pressing off ⇒ page 121
❑ Pressing on ⇒ page 123
12 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
❑ Redetermine thickness if synchro-hub is replaced ⇒ page 121
13 - NeedleProtected
bearing by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For 2nd gear
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - Locking collar for 1st and 2nd gear
❑ Installation position ⇒ page 123
15 - Synchro-ring for 2nd gear
❑ Checking for wear ⇒ page 123
16 - Spring
❑ Insert in 2nd speed selector gear ⇒ page 123
❑ Allocation to selector gear ⇒ Electronic parts catalogue
17 - 2nd speed selector gear
18 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
19 - 3rd gear wheel
❑ Pressing off ⇒ page 120
❑ Groove faces 4th gear
❑ Pressing on ⇒ page 124
20 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
❑ If the 3rd gear wheel is renewed redetermine thickness ⇒ page 121
21 - 4th gear wheel
❑ Pressing off ⇒ page 120
❑ Shoulder faces towards 3rd gear
❑ Pressing on ⇒ page 124
❑ Reinforcements on gearboxes manufactured from 17 08 8 onwards ⇒ page 126

114 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

22 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
❑ If the 4th gear wheel is renewed redetermine thickness ⇒ page 121
❑ Reinforcements on gearboxes manufactured from 17 08 8 onwards ⇒ page 126
23 - Needle bearing
❑ For 5th gear
❑ Reinforcements on gearboxes manufactured from 17 08 8 onwards ⇒ page 126
24 - 5th speed selector gear
❑ Reinforcements on gearboxes manufactured from 17 08 8 onwards ⇒ page 126
25 - Spring
❑ Insert in 5th speed selector gear ⇒ page 123
❑ Allocation to selector gear ⇒ Electronic parts catalogue
26 - Synchro-ring for 5th gear
❑ Checking for wear ⇒ page 123
27 - Circlip
❑ Mark
❑ Installation position ⇒ page 122
28 - 5th gear and reverse gear synchro-hub
❑ Pressing off ⇒ page 120
❑ Pressing on ⇒ page 124
❑ Installation position: high inside collar faces 5th speed selector gear
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
29 - Circlip permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Mark
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Installation position ⇒ page 122

❑ Redetermine thickness if synchro-hub is replaced ⇒ page 121
30 - Needle bearing
❑ For reverse gear
31 - 5th and reverse gear locking collar
❑ Installation position ⇒ page 125
32 - Synchro-ring for reverse gear
❑ Checking for wear ⇒ page 123
33 - Spring
❑ Insert into reverse selector gear ⇒ page 123
❑ Allocation to selector gear ⇒ Electronic parts catalogue
34 - Reverse selector gear
35 - Inner race for small tapered roller bearing 1)
❑ Pressing off ⇒ page 120
❑ Pressing on ⇒ page 125
36 - Bush
❑ Secures outer race for small tapered roller bearing
❑ Pulling out ⇒ page 118
❑ Need not be refitted after the small tapered roller bearing has been renewed
37 - Outer race for small tapered roller bearing 1)
❑ Pulling out ⇒ page 119
❑ Pressing in ⇒ page 119

2. Pinion shaft 115

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

38 - Shim „S4“
❑ Table of adjustments ⇒ page 152
39 - Pressure plate
❑ Different thicknesses for aluminium and magnesium gearboxes ⇒ page 126
40 - Rubber disc
❑ Compensates length variations
❑ To remove, screw self-tapping screw into centre of disc and use screw to pull out disc
❑ Different thicknesses for aluminium and magnesium gearboxes ⇒ page 126
❑ Select correct version according to gearbox code letters ⇒ Electronic parts catalogue ⇒ page 2
41 - Gearbox cover
❑ Aluminium version must only be fitted to an aluminium gearbox housing
❑ Magnesium version must only be fitted to a magnesium gearbox housing
❑ Note identification markings ⇒ page 84
❑ Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-

2.2 Dismantling and assembling pinion shaft

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-
♦ Press tool -VW 412-
♦ Tube -VW 415 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

116 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Crankshaft seal installing

tool -VW 204 B-
♦ Tube -VW 421-
♦ Installing sleeve -VW 455-
♦ Tube -VW 519-
♦ Multi-purpose tool -
VW 771-
♦ Tube -2010-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Pinion shaft 117

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Thrust plate -3005-

♦ Press tool -3118-
♦ Fitting tool -3128-
♦ Assembly tool -3301-
♦ -1- Internal puller -Kukko
21/1-
♦ -1- Internal puller -Kukko
21/4-
♦ -3- Splitter -Kukko 17/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Inductive heater -
VAS 6414-

Pulling out securing

bush for outer race for
small tapered roller bear‐
ing
A - Internal puller 12 ...
16 mm , e.g. -Kukko
21/1-

118 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pulling out outer race for small tapered roller bearing

– Screw adapter -VW 771/40- into pressure plate.
– Attach multi-purpose tool -VW 771- and pull outer race out via
the pressure plate.

Pressing in outer race for small tapered roller bearing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pulling out outer race for large tapered roller bearing

– Remove differential ⇒ page 137 .
– Place thrust piece of fitting tool -3128- below the outer race.
– Fit threaded spindle and thrust pad of assembly tool -3301-
with thrust plate -VW 401- onto gearbox housing.
The outer race will be pulled out of the housing when the bolt is
tightened.

Pressing in outer race for large tapered roller bearing

The smaller diameter of the crankshaft seal installing tool -VW
204 B- faces towards the outer race.

2. Pinion shaft 119

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressing off inner race for small tapered roller bearing

– Press off inner race with reverse gear selector gear
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Pressing off 5th gear and reverse gear synchro-hub

– Remove circlip before pressing off.
– Press off synchro-hub with 5th speed selector gear.
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing off 4th gear wheel

– Remove circlip before pressing off.

Pressing off 3rd gear wheel

– Remove circlip before pressing off.
– Press off 3rd gear wheel with 2nd speed selector gear.
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

120 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressing off 1st and 2nd gear synchro-hub

– Remove circlip before pressing off.
– Press off synchro-hub with 1st speed selector gear.

Pressing off inner race for large tapered roller bearing

– Remove circlip before pressing off.
– The outer race -A- must be fitted to press off the inner race.

Pressing on inner race for large tapered roller bearing

Determining thickness of circlip

– Determine the thickest circlip that will just fit and install it.
The circlips for the synchro-hubs and individual gear wheels
should also be determined as shown for the tapered roller bear‐
ing.
For available circlips and part numbers refer to ⇒ Electronic parts
catalogue .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Pinion shaft 121

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installation position of circlips

Note

Select correct circlips from ⇒ Electronic parts catalogue .

– The required circlips for the synchro-hubs, needle bearings

and individual gear wheels should be selected as shown in
⇒ page 121 .
♦ Circlip -1- secures inner race for tapered roller bearing.
Circlip thickness (mm)
2.00 2.06 2.12
2.03 2.09 2.15
♦ Circlip -2- secures the 1st and 2nd gear synchro-hub.
Identification: blue colour
Circlip thickness (mm)by AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised

1.90 1.96 2.02

with respect to the correctness of information in this document. Copyright by AUDI AG.

1.93 1.99
♦ Circlip -3- secures the needle bearing for 2nd speed selector
gear.
Identification: blue colour
Circlip thickness (mm)
2.50
♦ Circlip -4- secures the 3rd gear wheel.
Circlip thickness (mm)
1.90 1.98 2.06
1.94 2.02

♦ Circlip -5- secures the 4th gear wheel.

Circlip thickness (mm)
1.86 1.94
1.90 1.98
♦ Circlip -6- secures the needle bearing for 5th speed selector
gear.
Identification: brown colour
Circlip thickness (mm)
2.00
♦ Circlip -7- secures the synchro-hub for 5th and reverse gear.
Identification: blue colour
Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05

122 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Inserting spring in selector gear

The bent end of the spring -arrow- must be hooked into the hole
in the selector gear.

Checking synchro-ring for wear

– Press synchro-ring into locking collar and measure gap -a-
with a feeler gauge at positions -A-, -B- and -C-.
– Add the measured values and divide by 3.
The average gap must not be less than 0.5 mm.

Heating 1st and 2nd gear synchro-hub and pressing on

♦ Installation position:
Higher inside collar faces 2nd gear.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation position of locking collar for 1st and 2nd gear

♦ Installation position:
Chamfered surface -arrow 1- faces towards 2nd gear.
Shoulder -arrow 2- faces towards 1st gear.

2. Pinion shaft 123

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Heating 3rd gear wheel and pressing on

♦ Installation position:
Groove on gear wheel faces towards 4th gear.

Heat 4th gear wheel and press on.

♦ Installation position:
Higher inside collar faces 3rd gear.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Heating synchro-hub for 5th gear and reverse gear and pressing
on
♦ Installation position:
Higher inside collar faces 5th gear.

Note

The large internal diameter in tube -2010- faces towards synchro-

hub.

124 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installation position of locking collar for 5th and reverse gear

Different types of locking collar are installed: version -A- with
chamfered surface -arrow 1- or version -B- with large shoulder
-arrow 3-.
♦ Make sure locking collar is correct version for reverse gear
wheel ⇒ page 125 .
♦ Installation position:
Chamfered surface -arrow 1- faces towards reverse gear.
Small shoulder -arrow 2- faces towards 5th gear.
Large shoulder -arrow 3- faces towards reverse gear.

Pressing on inner race for small tapered roller bearing

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Selecting correct locking collar for reverse gear wheel

-Arrow A- reverse Both types of locking collar can be instal‐
gear wheel with led (with chamfered surface or with large
chamfered surface shoulder)
-Arrow B- reverse Install only locking collar with large shoul‐
gear wheel without der; do not use locking collar with cham‐
chamfered surface fered edge

2. Pinion shaft 125

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressure plate identification

Gearbox housing Dimension -a-
Aluminium 14.8 or 15.3 mm
Magnesium ⇒ page 2 10.7 mm

Identification of rubber discs

Gearbox housing Dimension
Protected -a-Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Aluminium with 7.0 mm
respect to the correctness of information in this document. Copyright by AUDI AG.

Magnesium 11.0 mm

2.3 Reinforcements from 08.98 onwards

(from gearbox manufacturing date 17 08
8 onwards) in area of 4th gear wheel
The following components are affected by this modification:
1- Pinion shaft, identification ⇒ page 127
2- 4th gear wheel, identification ⇒ page 127
3- Circlip ⇒ page 127
4- Needle bearing ⇒ page 127
5- 5th selector gear, identification ⇒ page 127

Note

♦ Components from gearboxes with reinforced 4th gear and

components from gearboxes without reinforced 4th gear must
never be installed together; for allocation of parts, refer to ⇒
Electronic parts catalogue .
♦ Dismantling and assembly of the new parts is carried out as
described in the Workshop Manual.

126 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Distinguishing features of the pinion shafts

Pinion shaft -1- Pinion shaft -2-
new version from 08.98 old version up to 08.98
onwards
For reinforced 4th gear For non-reinforced 4th
wheel gear wheel
Dimension approx. 27.5 mm approx. 23.8 mm
-a-
Dimension approx. 40.0 mm approx. 43.5 mm
-b-
-Arrow 3- - With projection above
splines
-Arrow 4- With chamfered edges -
below splines

Distinguishing features of circlips and gear wheels

Circlip -1- -2-
New version from Old version up to
08.98 onwards 08.98
Dimension -a- approx. 34.5 mm approx. 38.0 mm

4th gear wheel -3- -4-

New version from Old version up to
08.98 onwards 08.98
Dimension -b- approx. 40.0 mm 43.5 mm

Distinguishing features of needle bearings and 5th selector gears

Needle bearing -1- -2-
New version from Old version up to
08.98 onwards 08.98
Dimension -a- approx. 26.8 mm approx. 24.8 mm

5th speed selector -3- -4-

gear New version from Old version up to
08.98 onwards 08.98
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Without shoulder With shoulder
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
-arrow-

2. Pinion shaft 127

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3 Removing and installing reverse gear wheel

1 - Circlip
2 - Support plate
3 - Reverse gear wheel
❑ Different versions; allo‐
cation ⇒ page 125
4 - Needle bearing
5 - Thrust washer
6 - Gearbox cover
❑ Aluminium version must
only be fitted to an alu‐
minium gearbox hous‐
ing
❑ Magnesium version
must only be fitted to a
magnesium gearbox
housing
❑ Note identification
markings ⇒ page 84
❑ With reverse gear shaft
-arrow-
❑ To remove the reverse
gear wheel it is not nec‐
essary to remove the re‐
verse gear shaft.
❑ The reverse gear shaft
is not available as a re‐
placement part.
❑ Coat sealing surfaces
lightly with sealing paste
-AMV 188 001 02-
7 - TORX bolt
❑ Serves as an additional
method of securing the
reverse gear shaft
❑ Bolt is made of different materials for aluminium and magnesium gearboxes.
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Tighten to 35 Nm on aluminium gearboxes
❑ Tighten to 25 Nm on magnesium gearboxes

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

128 Rep. gr.35 - Gears, shafts

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

39 – Final drive - differential

1 Renewing oil seals for flange shafts
• Gearbox in vehicle
– Refer to general repair instructions ⇒ page 12 .
Special tools and workshop equipment required
♦ Drift -VW 295-

♦ Oil seal extractor lever -VW 681- or extractor tool -T20143-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Puller -T10037-

1. Renewing oil seals for flange shafts 129

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Thrust piece -T10387-

♦ Used oil collection and extraction unit -V.A.G 1782-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Sealing grease -G 052 128 A1-

Removing flange shaft oil seal

Note

♦ The procedure for removing the oil seals is identical on both

sides.
♦ The exhaust system does not have to be removed.
♦ Flange shaft may be with or without a polygon bearing
⇒ page 132 ; allocation
⇒ „1.2 Code letters, allocation, transmission ratios, capaci‐
ties“, page 2 .

– If fitted, remove noise insulation beneath gearbox.

– If fitted, detach heat shield for drive shaft.
– Turn steering to left onto full lock.
– Unbolt drive shaft from gearbox flange shaft ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 40 .
– Tie-up drive shaft as high as possible. Do not damage paint
on drive shaft.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
derneath.

Note

In order to prevent damage to the needle bearings (polygon bear‐

ings) or the differential during removal, the flange shaft must be
kept straight when removing (pull out evenly).

130 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

When renewing oil seal (left-side):

– Remove flange shaft, to do so, secure puller -T10037- to cover
for final drive -arrow-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

When renewing oil seal (right-side):

– Remove flange shaft; to do so, secure puller -T10037- to gear‐
box housing -arrow-.
Both sides
– Pull out flange shaft oil seal using oil seal extractor lever -
VW 681- or extractor hook -T20143- .

– Always renew flange shaft retaining ring.

– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.

1. Renewing oil seals for flange shafts 131

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Assembling flange shaft with polygon bearing

1- Flange shaft
2- Needle bearing (polygon bearing)
3- Spacer ring
4- Circlip
5- Spacer ring - fitted additionally on shafts with 30 mm spline
diameter

Note

♦ If the polygon bearings do not run smoothly with the flange

shaft removed, this does not necessarily indicate that the
bearings are defective. A test for noisy bearings can only be
performed with the bearings installed.
♦ Inspect for signs of damage to polygon bearings (such as
cracking in outer race).
♦ The polygon bearings can only be renewed together with the
flange shaft.
♦ A spacer ring -5- is fitted between the polygon bearing and the
differential sun wheel on flange shafts with 30 mm spline di‐
ameter.

Installing flange shaft oil seal

– Lightly oil outer circumference of new oil seal.

– Drive in new flange shaft oil seal (left-side) using thrust piece
-T10387- until thrust piece reaches stop; keep seal straight
when installing.

Note

♦ Driving-in depth (standard): 5.5 mm beneath surface of cover

♦ When carrying out a repair, the oil seal is driven in to a depth
of 6.5 mm using thrust piece -T10387- , so that the new seal
does not bear on the same contact surface on the used flange
shaft.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

132 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Drive in new flange shaft oil seal (right-side) using thrust piece
-T10387- until thrust piece reaches stop; keep seal straight
when installing.

Note

♦ Driving-in depth (standard): 5.5 mm beneath surface of cover

♦ When carrying out a repair, the oil seal is driven in to a depth
of 6.5 mm using thrust piece -T10387- , so that the new seal
does not bear on the same contact surface on the used flange
shaft.

– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Knock flange shaft in with drift -VW 295- .
The remaining installation steps are carried out in the reverse se‐
quence; note the following points:
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Check gear oil level in gearbox ⇒ page 78 .
– If originally fitted, bolt on heat shield for drive shaft.
– If originally fitted, install noise insulation panels.
Tightening torque
Component Nm
Heat shields for drive shafts to gearbox 23

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Renewing oil seals for flange shafts 133

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

2 Removing and installing speedome‐

ter sender and drive wheel
• Gearbox in vehicle
– Refer to general repair instructions ⇒ page 12 .

2.1 Removing and installing speedometer

sender -G22-
Removing
– Unplug connector from speedometer sender -A-.
– Press down retainer, swivel speedometer sender aside and
take out upwards.
Installing
– Install new O-ring -B-.
– Insert speedometer sender -A- and engage.
– Take care not to damage speedometer sender . Speedometer
reading may be inaccurate if sender is damaged.

2.2 Removing and installing speedometer

drive wheel
Special tools and workshop equipment required
♦ Drift -VW 295-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Oil seal extractor lever -VW 681- or extractor tool -T20143-

134 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Puller -T10037-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with♦respect
Used oilcorrectness
to the collection and extraction
of information unitCopyright
in this document. -V.A.G 1782-
by AUDI AG.

Removing
– If fitted, remove noise insulation beneath gearbox.
– If fitted, detach heat shield for drive shaft.
– Turn steering to left onto full lock.
– Unbolt drive shaft from gearbox flange shaft ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 40 .
– Tie-up drive shaft as high as possible. Do not damage paint
on drive shaft.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
derneath.

Note

In order to prevent damage to the needle bearings (polygon bear‐

ings) or the differential during removal, the flange shaft must be
kept straight when removing (pull out evenly).

2. Removing and installing speedometer sender and drive wheel 135

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Remove flange shaft, to do so, secure puller -T10037- to cover

for final drive -arrow-.
– Pull out flange shaft oil seal using oil seal extractor lever -
VW 681- or extractor hook -T20143- .
– Remove speedometer sender -G22- ⇒ page 134 .

– Press retaining clips in direction of -arrows- with a screwdriver.

– Remove drive wheel by levering out, alternating between
sides.
Installing
Installation is carried out in reverse sequence; note the following:

Note

Fit the drive wheel carefully onto the differential, making sure that
it is kept straight. Do not use force; the drive wheel can break
easily.

Installation position:

The drive peg of the drive wheel -A- faces towards oil seal -B- and
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

locates in the slot on the differential.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

The retaining clips -arrows- locate in the annular groove in the

differential.
– Always renew circlip -C- for flange shaft ⇒ page 131 .
– Install new flange shaft oil seal -B- ⇒ page 132 .
– Knock flange shaft in with drift -VW 295- .
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Check gear oil level in gearbox ⇒ page 78 .
– If originally fitted, bolt on heat shield for drive shaft.
Tightening torque
Component Nm
Heat shields for drive shafts to gearbox 23

136 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

3 Differential
Overview
♦ ⇒ „3.1 Removing and installing differential“, page 137
♦ ⇒ „3.2 Dismantling and assembling differential“, page 141

3.1 Removing and installing differential

♦ Multi-purpose tool -
VW 771-
♦ Socket (27 mm) -3257-
♦ Torque wrench -
V.A.G 1331-
♦ -1- Internal puller -Kukko
21/3-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 137
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ Removing and installing is possible with the gearbox installed.

♦ The differential can be removed and installed without removing the selector mechanism, input shaft, pinion
shaft and gearbox cover. These components must be removed if the differential needs to be adjusted.
♦ Flange shaft may be with or without a polygon bearing; allocation ⇒ page 2 .
♦ The polygon bearings can only be renewed together with the flange shaft.
♦ InspectProtected
polygon bearings for visible damage.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate
with respect to the correctness of information in this document. Copyright by AUDI AG.

that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.
♦ A spacer ring is fitted between the polygon bearing and the differential sun wheel on flange shafts with
30 mm spline diameter ⇒ page 140 .
♦ Adjustment work is required when renewing the parts marked with 1)
⇒ „4.3 Table of adjustments“, page 152 .

1 - Gearbox housing 1)
❑ Housing manufactured
from aluminium or mag‐
nesium
⇒ Item 14 (page 84)
❑ Aluminium version must
only be fitted to an alu‐
minium gearbox cover
❑ Magnesium version
must only be fitted to a
magnesium gearbox
cover
2 - Oil seal
❑ Renewing ⇒ page 129
3 - Circlip
❑ Renew
❑ Removing and installing
⇒ page 139
4 - Spacer ring
❑ Is only fitted on flange
shafts with polygon
bearings and a spline di‐
ameter of 30 mm
⇒ page 140
❑ Removing ⇒ page 139
❑ Installing ⇒ page 140
5 - Flange shaft
❑ Removing and installing
⇒ page 129
❑ Assembling flange shaft
with polygon bearing
⇒ page 140
6 - Differential with crown
wheel 1)
❑ Can be removed without removing gearbox
❑ Dismantling and assembling ⇒ page 141
❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141

138 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

7 - Cover for final drive 1)

❑ Aluminium version must only be fitted to an aluminium gearbox housing
❑ Magnesium version must only be fitted to a magnesium gearbox housing
❑ Identification ⇒ page 140
❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-
8 - TORX bolt
❑ 25 Nm
❑ Always renew
❑ On aluminium version: black, M8 x 42, without washer
❑ For magnesium gearboxes up to approx. 09.97: bright metal, M8 x 45, fit washer with each bolt
❑ On magnesium version from 09.97 onwards (introduced gradually): bright metal, different bolt lengths
⇒ page 140
9 - Speedometer drive wheel
❑ Removing and installing ⇒ page 134
❑ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force;
the drive wheel can break easily

Removing and installing circlip

– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.

Removing spacer ring

A - Internal puller 18.5 ... 23.5 mm , e.g. -Kukko 21/3-
– If the spacer ring is tight, pull out using multi-purpose tool -
VW 771- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 139
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Installing spacer ring

– Drive new spacer ring in onto stop, taking care to keep ring
straight.

Assembling flange shaft with polygon bearing

1- Flange shaft
2- Needle bearing (polygon bearing)
3- Spacer ring
4- Circlip
5- Spacer ring - fitted additionally on shafts with 30 mm spline
diameter

Note

The needle bearings (polygon bearings) do not turn easily when

the flange shaft is removed. This does not indicate that a bearing
is defective.

Identification of final drive cover

On magnesium gearboxes »Mg Al 9 Zn 1« can be found in the
area indicated by the -arrow-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Mg = Magnesium; additional data is onlypermitted
for production.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Locations of bolts for final drive cover on gearboxes with magne‐

sium housing from approx. 09.97 onwards
1- Bright metal bolts, M8 x 42, without washer
2- Bright metal bolts, M8 x 45, with captive washer

Note

Only M8 x 45 bolts with captive washers are supplied as replace‐

ment parts. If required, these must be used for all securing bolts
on the final drive cover.

140 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Reinforcements from 08.98 onwards (tapered roller bearing with

larger inner and outer diameter) on left side of differential (crown
wheel side). The modification was introduced gradually from
gearbox manufacturing date 17 08 8 onwards but applies to all
gearboxes from gearbox manufacturing date 11 01 9 onwards.
The following components are affected by this modification:
1- Differential cage
2- Tapered roller bearing inner race
3- Tapered roller bearing outer race
4- Shim „S1“
5- Cover for final drive
Allocation of parts: ⇒ Electronic parts catalogue

3.2 Dismantling and assembling differential

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-
♦ Thrust plate -VW 447 H-
♦ Thrust plate -VW 447 i-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 141
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Press tool -VW 472/1-

♦ Thrust piece -2050-
♦ Drift -3138-
♦ Sleeve -3144-
♦ Tube -3296-
♦ Torque wrench -
V.A.G 1332-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

142 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Removal and installing tool

-VW 459-
♦ -1- Internal puller -Kukko
21/7-
♦ -4- Counter-support -Kukko
22/2-
♦ -3- Puller -Kukko 204/2-
♦ Two-arm puller -Kukko
44/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Inductive heater -VAS 6414-

3. Differential 143
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ Removing and installing differential ⇒ page 137

♦ Use inductive heater -VAS 6414- to heat tapered roller bearing inner race to 100°C before installing.
♦ Always renew both tapered roller bearings together.
♦ Adjustment work is required when renewing the parts marked with 1)
⇒ „4.3 Table of adjustments“, page 152 .

1 - Gearbox housing 1)
2 - Shim „S2“
❑ Note thickness
❑ Table of adjustments
⇒ page 152
3 - Outer race for tapered roller
bearing (right-side) 1)
❑ Pulling out ⇒ page 145
❑ Pressing in
⇒ page 146
4 - Inner race for tapered roller
bearing (right-side) 1)
❑ Pulling off ⇒ page 146
❑ Pressing on
⇒ page 146
5 - Crown wheel1)
❑ Is paired with pinion
shaft (final drive gear
set)
❑ Select correct version
according to gearbox
code letters ⇒ Electron‐
ic parts catalogue
⇒ page 2
❑ Drive crown wheel off
differential cage using a
punch ⇒ page 148
❑ Fitting on differential
cage ⇒ page 148
6 - Differential cage1)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Select correct
permitted version
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
according to gearbox
with respect to the correctness of information in this document. Copyright by AUDI AG.

code letters ⇒ Electron‐

ic parts catalogue ⇒ page 2
❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141
7 - Bolt
❑ 60 Nm and turn 45° further
❑ Renew
❑ Tighten bolts in stages and in diagonal sequence until crown wheel makes full contact with differential
cage. Then tighten to specified torque.
8 - Inner race for tapered roller bearing (left-side) 1)
❑ Pulling off ⇒ page 147
❑ Pressing on ⇒ page 146

144 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141

❑ For correct version, refer to ⇒ Electronic parts catalogue
9 - Speedometer drive wheel
❑ Removing and installing ⇒ page 134
❑ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force;
the drive wheel can break easily.
10 - Outer race for tapered roller bearing (left-side) 1)
❑ Driving out ⇒ page 147
❑ Pressing in up to approx. 08.98 ⇒ page 147
❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141
❑ Pressing in from 08.98 onwards ⇒ page 148
❑ For correct version, refer to ⇒ Electronic parts catalogue
11 - Shim „S1“
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Notepermitted
thicknessunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Table of adjustments ⇒ page 152
❑ For correct version, refer to ⇒ Electronic parts catalogue
12 - Cover for final drive 1)
❑ Aluminium version must only be fitted to an aluminium gearbox housing
❑ Magnesium version must only be fitted to a magnesium gearbox housing
❑ From 08.98 onwards: reinforcements (introduced gradually) ⇒ page 141
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-
13 - Sun wheel
❑ Installing ⇒ page 148
14 - Differential pinion pin
❑ Drive out with drift after removing spring pin
15 - Spring pin
❑ Secures differential pinion pin
❑ Version with annular groove: removing and installing ⇒ page 149
❑ Version without annular groove: knock out with punch
16 - Planet pinion
❑ Installing ⇒ page 148
17 - One-piece thrust washer
❑ Lubricate with gear oil before installing

Pulling tapered roller bearing outer race out of gearbox housing

A - Counter-support , e.g. -Kukko 22/2-
B - Internal puller 46 ... 58 mm , e.g. -Kukko 21/7-
– After removing, check shims for damage.

3. Differential 145
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressing tapered roller bearing outer race (right-side) into gear‐

box housing
– The taper of press tool -VW 472/1- is applied in the outer race.
– Support gearbox housing with -VW 459/2- directly below bear‐
ing mounting.

Note

Use thrust plate -30 - 205- in place of press tool -VW 472/1- on
gearboxes which have flange shafts without polygon bearings.

Pulling off inner race for tapered roller bearing (right-side)

A - Two-arm puller , e.g. -Kukko 44/2- or -Kukko 20/10-

Note

♦ If using a puller with small-diameter spindle, thrust plate -30 -

11- must also be fitted between thrust plate -VW 447 H- and
puller.
♦ Use thrust plate -40 - 105- in place of thrust plate -VW 447 H-
on gearboxes which have flange shafts without polygon bear‐
ings.
♦ There is a slot under the bearing seat in the differential cage
for applying puller -A-.

Pressing on inner race for tapered roller bearing (right-side)

WARNING

Wear protective gloves.

– Heat inner race to approx. 100 °C, fit in position and press
home. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Use press tool -40 - 21- in place of tube -3296- on gearboxes

which have flange shafts without polygon bearings.

146 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pulling off inner race for tapered roller bearing (left-side)

A - Two-arm puller , e.g. -Kukko 204/2-

Note

♦ If using a puller with small-diameter spindle, thrust plate -30 -

11- must also be fitted between thrust plate -VW 447 H- and
puller.
♦ Use thrust plate -40 - 105- in place of thrust plate -VW 447 H-
on gearboxes which have flange shafts without polygon bear‐
ings. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ There is a slot under the bearing seattointhethe
with respect differential
correctness cage
of information in this document. Copyright by AUDI AG.
for applying puller -A-.

Fitting inner race for tapered roller bearing (left-side)

WARNING

Wear protective gloves.

– Heat inner race to approx. 100 °C, fit in position and press
home.

Note

Use press tool -40 - 21- in place of tube -3296- on gearboxes

which have flange shafts without polygon bearings.

Knocking outer race for tapered roller bearing (left-side) out of

cover
– Turn the lugs -A- and -B- out until they bear against the outer
race within the recess in the housing.
– After removing, check shims for damage.

Pressing tapered roller bearing outer race (left-side) into cover on

gearboxes without reinforcements
– The taper of press tool -VW 472/1- is applied in the outer race.

Note

Use thrust pad -VW 511- in place of thrust plate -VW 472/1- on
gearboxes which have flange shafts without polygon bearings.

3. Differential 147
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Pressing tapered roller bearing outer race (left-side) into cover on

gearboxes with reinforcements from 08.98 onwards
– Press outer race for tapered roller bearing (left-side) into cover
using thrust piece -2050- .
– The shoulder of thrust piece -2050- is applied in the outer race.

Driving crown wheel off differential cage

Heating crown wheel to approx. 100 °C and installing

WARNING

Wear protective gloves.

– When fitting crown wheel, use centralising pins -A- (shop-

made tool) to locate.
– Allow to cool slightly before screwing in new securing bolts.
– Then tighten bolts in stages and in diagonal sequence until
crown wheel makes full contact with differential cage.
– Then tighten bolts to specified torque ⇒ Item 7 (page 144) .

Installing
Protected by differential bevel
copyright. Copying gears
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– with
Lubricate one-piece
respect to the thrust
correctness of washer
information with gear
in this document. oil and
Copyright install.
by AUDI AG.

– Fit sun wheels.

– Insert planet pinions (spaced 180° apart) and pivot into posi‐
tion -arrow-.
– Drive differential pinion pin into final position and secure.

148 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Removing and installing spring pin

Removing
– Spring pin with annular groove: pull out using side-cutting pli‐
ers.
– Spring pin without annular groove: knock out from behind us‐
ing a punch.
Installing
– Drive in spring pin as far as the stop.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 149
 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

4 Adjusting pinion shaft and crown

wheel

Note

♦ Careful adjustment of the crown wheel and pinion shaft is es‐

sential to ensure that the final drive gives long service and runs
silently. For this reason, the pinion shaft and crown wheel are
matched together during manufacture, and checked to ensure
a good mesh pattern and quiet running in both directions of
rotation. The position of quietest running is found bybymoving
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
the pinion shaft in an axial direction and at the same
permittedtime
unlesslifting
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the crown wheel out of the zero-play mesh position by the
with respect to the correctness of information in this document. Copyright by AUDI AG.
amount necessary to maintain the backlash within the speci‐
fied tolerance.
♦ The object of the adjustment is to reproduce the setting for
quietest possible running, as obtained on the test machine in
production.
♦ The allowance „r“ in relation to the master gauge „Ro“ is meas‐
ured for the final drive gear sets supplied as replacement parts
and marked on the outer circumference of the crown wheel.
The final drive gear set (pinion shaft and crown wheel) may
only be renewed together as a matched pair.
♦ Observe the general repair instructions for tapered roller bear‐
ings and shims ⇒ page 12 .

4.1 Adjustment and marking of final drive gear set

150 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

1 - Identification „0937“ de‐

notes an Oerlikon gear set with
a ratio of 37 : 9.
2 - -312- number of matched
pair of gears
3 - Allowance „r“ is based on
the master gauge used on the
test machine in production.
The allowance „r“ is always
given in 1/100 mm. For exam‐
ple: „25“ indicates r = 0.25 mm
Ro - Length of master gauge
used on test machine in pro‐
duction.
❑ Crown wheel ∅ 170 mm
= 54.95 mm
❑ Crown wheel ∅ 180 mm
= 59.65 mm
R - Actual distance between
centre axis of crown wheel and
face of pinion shaft in position
of quietest running for this gear
set
Vo - Hypoid offset

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Adjusting pinion shaft and crown wheel 151

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

4.2 Position of shims

Note

Table of adjustments when renewing individual components of gearbox ⇒ page 152 .

S1 - Shim for crown wheel in

cover for final drive
S2 - Shim for crown wheel in
gearbox housing
S3 - Shim for pinion shaft in
gearbox housing
S4 - Shim for pinion shaft in
gearbox cover

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.3 Table of adjustments

Note

If repairs have been carried out to the gearbox, it is only necessary

to adjust the pinion shaft, crown wheel or final drive set if com‐
ponents have been renewed which have a direct effect on the
adjustment of the final drive. Refer to the following table to avoid
unnecessary adjustment work:

Components requiring adjustment: Crown wheel Pinion shaft Pinion shaft Backlash
(„S1“ + „S2“) („S3“ + „S4“) via Shim „S4“ only 0.12 - 0.22 mm
allowance „r“
⇒ page 165 ⇒ page 153 ⇒ page 162 ⇒ page 169

152 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Component renewed
Gearbox housing 1) X X X
Gearbox cover X
Differential cage X X
Tapered roller bearings for pinion X X
shaft
Tapered roller bearings for differential X X
Final drive gear set 2) X X X
Cover for final drive X
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
X
1) If the gearbox housing is
renewed the input
permitted shaft
unless mustbyalso
authorised AUDI AG.be AUDI
adjusted
AG does⇒ notpage 110
guarantee .
or accept any liability
2) with respect to the correctness of information in this document. Copyright by AUDI AG.
If necessary, pinion shaft and crown wheel must always be renewed together.

4.4 Re-adjustment sequence for final drive

gear set
The following work sequence is recommended to save time when
the crown wheel and pinion shaft have to be adjusted:
♦ Determine total shim thickness „Stotal“ (S1 plus S2) for speci‐
fied preload on tapered roller bearings for differential
⇒ page 167 .
♦ Determine total shim thickness „Stotal“ (S3 plus S4) for speci‐
fied preload on tapered roller bearings for pinion shaft
⇒ page 155 .
♦ Distribute total shim thickness „Stotal“ (S3 plus S4) so that di‐
mension from centre of crown wheel to end face of pinion
corresponds to installation dimension „R“ determined during
production ⇒ page 161 .
♦ Distribute total shim thickness „Stotal“ (S1 plus S2) so that
specified backlash between crown wheel and pinion shaft is
obtained ⇒ page 171 .

Note

Overview of components and shims ⇒ page 152 .

4.5 Adjusting pinion shaft

4. Adjusting pinion shaft and crown wheel 153

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Special tools and workshop

equipment required
♦ Crankshaft seal installing
tool -VW 204 B-
♦ Removal lever -VW 296-
♦ Universal measuring tool -
VW 385-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Thrust plate -VW 401-
♦ Press tool -VW 407-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

154 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Tube -VW 519-

♦ Assembly device -VW 792-
♦ Thrust plate -3005-
♦ Fitting tool -3128-
♦ Assembly tool -3301-
♦ Torque wrench -
V.A.G 1331-

The pinion shaft only needs to be re-adjusted according to the

following instructions if the final drive set, the tapered roller bear‐
ings for the pinion shaft or the gearbox housing are being re‐
newed. Table of adjustments ⇒ page 152
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The
permitted object of the by
unless authorised adjustment
AUDI AG. AUDIis AGto reproduce
does not guaranteethe setting
or accept for qui‐
any liability

etest possible running, as obtained on the test machine in pro‐

with respect to the correctness of information in this document. Copyright by AUDI AG.

duction. For good results, maximum care and cleanliness are very
important when performing repairs and taking measurements.
Determining total shim thickness „Stotal“ for shims „S3“ plus
„S4“
(Setting preload of tapered roller bearings for pinion shaft)
• Differential removed

4. Adjusting pinion shaft and crown wheel 155

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Install outer race for large tapered roller bearing without shims
in gearbox housing.
– Fit rubber disc ⇒ Item 40 (page 116) and pressure plate
⇒ Item 39 (page 116) in gearbox cover.
Pressure plates and rubber discs with different thicknesses can
be installed:
Gearbox housing Thickness of pres‐ Thickness of rubber
sure plate disc
Aluminium 14.8 or 7.0 mm
15.3 mm

Gearbox housing Thickness of pres‐ Thickness of rubber

sure plate disc
Magnesium 10.7 mm 11.0 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Press the outer with

race for tosmall tapered roller bearing together
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect the correctness of information in this document. Copyright by AUDI AG.
with a 0.85 mm thick provisional shim „S4*“ fully into the gear‐
box cover.

Note

For measurement purposes a shim „S4“ with a thickness of 0.85

mm is inserted provisionally. This is referred to in the following as
„S4*“. „S4*“ is exchanged with the final shim „S4“ after determin‐
ing measured value „e“.

– Press on inner race for large tapered roller bearing

⇒ page 121 .

– Secure lower tapered roller bearing -arrow- ⇒ page 121 .

Note

Pinion shaft is shown in illustration with gears removed.

– Assemble pinion shaft ⇒ page 116 .

– Insert completely assembled pinion shaft in gearbox housing.
– Fit gearbox cover and tighten bolts to 22 Nm.
– Turn gearbox so that the gearbox cover points downwards.

– Press down on face of pinion shaft with transmission removal

lever -VW 296- until the outer race for the tapered roller bear‐
ing contacts the gearbox cover.
– Keep pressing down on the face of the pinion shaft, and at the
same time rotate the pinion shaft 8 times by hand to allow the
tapered roller bearing to settle.

156 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Mount dial gauge (3 mm measuring range) and set to „0“ with

2 mm preload.
– Use dial gauge extension (length 30 mm).

Note

The dial gauge extension must contact the machined surface on

the face of the pinion.

– Turn gearbox 180° so that the gearbox cover faces upwards.

– Rotate pinion shaft 5 turns in each direction so that the bearing
settles.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Adjusting pinion shaft and crown wheel 157

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Read off play on dial gauge and note reading.

♦ Measurement in example: 0.55 mm

Note

If the measuring procedure needs to be repeated, the pinion shaft

must first be rotated 5 turns in each direction again so that the
tapered roller bearing seats properly. Preload dial gauge to 2 mm
and set to „0“ again.

Formula: „Stotal“ = „S4*“ + measured value + bearing preload

Example:
Inserted shim „S4*“ 0.85 mm
+ Measured value (example) 0.55 mm
+ Bearing preload (constant value) 0.15 mm
= Total shim thickness„Stotal“ for „S3“ + „S4“ 1.55 mm

Determining thickness of provisional shim „S3*“

Note

Provisional shim S3* is replaced with final shim S3 after deter‐

mining measured value „e“.

Formula: „S3*“ = „Stotal“ – „S4*“

Example:
Total shim thickness„Stotal“ for „S3“ + „S4“ 1.55 mm
- Inserted shim „S4*“ 0.85 mm
= Thickness of shim „S3*“ 0.70 mm

– Remove outer race for large tapered roller bearing

⇒ page 119 .
– Fit provisional shim „S3*“ in gearbox housing and install outer
race again ⇒ page 119 .
– Insert completely assembled pinion shaft into gearbox housing
again.
– Fit gearbox cover and tighten bolts to 22 Nm.
Checking preloadProtected
of tapered roller bearings for pinion shaft
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Turn pinion shaft 5 turns in each direction so that tapered roller

with respect to the correctness of information in this document. Copyright by AUDI AG.

bearings seat properly.

Note

♦ If the pinion shaft cannot be turned by hand, screw an M10 x

20 bolt into the pinion head and turn the shaft by applying a
suitable tool to the bolt.
♦ Remove bolt after turning the shaft.

158 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Set up measuring tools and secure with bolt -arrow- to gearbox

housing.
– Apply dial gauge (3 mm measuring range) onto centre of gear‐
box cover and set to „0“ with 2 mm preload.
– Loosen gearbox cover bolts and turn pinion shaft several
times.
– If the correct shims have been selected the dial gauge will now
indicate the following value:
0.05…0.15 mm
– Tighten gearbox cover bolts again to 22 Nm.
– Take down measuring tools.
– Position M10 x 20 bolt on pinion shaft head and rotate pinion
shaft by 8 turns to settle tapered roller bearings.
– Remove bolt.
Determining dimension „e“

Note

Measurement „e“ is required to determine the final shim thickness

of „S3“ and „S4“.

– Set adjustment rings of universal measuring tool -VW 385/1-

to the following values:
♦ Dimension -a- = 35 mm
♦ Dimension -b- = 75 mm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Assemble universal measuring tool -VW 385/1- as illustrated.

Dial gauge extension A Ro Crown wheel
∅
6.5 mm 54.95 170 mm
9.3 mm e. g. -VW 385/15- 59.65 180 mm
Set master gauge -VW 385/30- to Ro according to crown wheel
∅ and fit onto universal measuring tool .
Crown wheel ∅ 180 mm Ro = 59.65 mm
Crown wheel ∅ 170 mm Ro = 54.95 mm
– Set dial gauge (3 mm measuring range) to „0“ with 2 mm pre‐
load.

Note

Use centring ring 61 mm -VW 385/2- in place of centring ring 69

mm -VW 385/3- opposite dial gauge on gearboxes which have
flange shafts without polygon bearings.

4. Adjusting pinion shaft and crown wheel 159

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Place end measuring plate on face of pinion gear.

Note

Ensure contact surface of end measuring plate fits exactly and is

free of oil.

– Detach master gauge and insert universal measuring tool in

housing.
♦ For Ro = 54.95 mm a 6.5 mm dial gauge extension must be
used instead of the dial gauge extension -VW 385/15- .
♦ The dial gauge faces towards the final drive cover
– Fit cover for final drive and tighten 4 bolts to 22 Nm.
– Using the adjustable ring, pull 2nd centring disc -VW 385/3-
out as far as possible so that the universal measuring tool can
still just be turned by hand.

Note

Use centring ring 61 mm -VW 385/2- in place of centring ring 69

mm -VW 385/3- opposite dial gauge on gearboxes which have
flange shafts without polygon bearings.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

160 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Turn universal measuring tool until tip of dial gauge touches

end measuring plate on face of pinion gear, and measure
maximum deflection (return point).
♦ Measurement in following example: „e“ = 0.33 mm (in red
scale)

Note

Then (after removing universal measuring tool ), check once

again that the dial gauge indicates „0“ with 2 mm preload when
master gauge -VW 385/30- is in place.

Determining thickness of shim „S3“

♦ The allowance „r“ referenced to the master gauge „Ro“ is
measured for the final drive gear sets supplied as replacement
parts and marked on the outer circumference of the crown
wheel.
♦ Subtract value „e“ if measurement is obtained on red scale.
♦ Add value „e“ if measurement is obtained on black scale.
Formula:
„S3“ = „S3*“ + „r“ + „e“ („e“ on black scale)
„S3“ = „S3*“ + „r“ – „e“ („e“ on red scale)

Example:
InsertedProtected
shim „S 3*“
by copyright.
0.70 mm
Copying for private or commercial purposes, in part or in whole, is not
+ Allowance „r“ 0.38 mm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- Determined value „e“ (in red scale) 0.33 mm
= Thickness of shim „S3“ 0.75 mm

– Determine shim(s) as accurately as possible according to ta‐

ble. For part numbers, refer to ⇒ Electronic parts catalogue .
Available shims for „S3“

Shim thickness (mm) 1)

0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
• 1)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

Determining thickness of shim „S4“

Formula: „S4“ = „Stotal“ – „S3“

Example:
Total shim thickness„Stotal“ for „S3“ + „S4“ 1.55
mm
- Thickness of shim „S3“ 0.75
mm
= Thickness of shim „S4“ 0.80
mm
– Determine shim(s) as accurately as possible according to ta‐
ble. For part numbers, refer to ⇒ Electronic parts catalogue .

4. Adjusting pinion shaft and crown wheel 161

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Shims available for „S4“

Shim thickness (mm) 1)

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73 0.89
• 1)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

Checking dimension „r“

– Install pinion shaft with determined shims „S3“ and „S4“ and
turn 5 turns in both directions.

– Insert universal measuring tool ⇒ page 159 and check adjust‐

ment.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Readwith
offrespect
dial togauge anti-clockwise
the correctness (red
of information in scale).Copyright by AUDI AG.
this document.

♦ If the shims have been correctly selected, the allowance

„r“ (marked on outer circumference of crown wheel) should be
indicated within a tolerance of ± 0.04 mm.

4.6 Re-determining shim „S4“ when renew‐

ing gearbox cover
Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-

162 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Assembly device -VW 792-

♦ Dial gauge , e.g. -VAS 6080-

♦ Dial gauge extension

♦ Depth gauge (accurate to within 5/100 mm or less)

♦ Sealing paste -AMV 188 001 02-

– Thoroughly clean contact surface of housing and bearing seat
on old and new gearbox covers.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Adjusting pinion shaft and crown wheel 163

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Measure difference in depth -a- on old and new gearbox cover.

Example:
Depth „a“ (old gearbox cover) 257.40 mm
Depth „a“ (new gearbox cover) 257.56 mm
= Difference 0.16 mm
– If new gearbox cover is deeper, install a thicker „S4“ shim.
– If previous gearbox cover is deeper, install a thinner „S4“ shim.
Example:
Previous shim „S4“ 0.69 mm
+ Difference 0.16 mm
= New shim „S4“ 0.85 mm

Shims available ⇒ page 162 .

– Press tapered roller bearing outer race with shim „S4“ into
gearbox cover ⇒ page 119 .
– Insert completely assembled pinion shaft into gearbox housing
again.
– Fit gearbox cover and tighten bolts to 22 Nm.
Checking preload of tapered roller bearings for pinion shaft
– Rotate pinion shaft 5 turns in each direction so that the bearing
settles.

Note

The pinion shaft can be rotated by turning both flange shafts to‐
gether.

– Set up measuring tools and secure with bolt -arrow- to gearbox

housing.
– Apply dial gauge (3 mm measuring range) onto centre of gear‐
box cover and set to „0“ with 2 mm preload.
– Loosen all gearbox cover bolts approx. one turn.
– If the correct shims have been selected the dial gauge will now
indicate the following value: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• 0.05…0.15 mm with respect to the correctness of information in this document. Copyright by AUDI AG.

If this reading is not obtained, the adjustment must be corrected.

– Detach measuring tools and gearbox cover.
– Clean sealing surfaces thoroughly for a second time and apply
a thin coat of sealing paste -AMV 188 001 02- .

Note

Check that the two dowel sleeves for centralising the gearbox
cover are fitted in the gearbox housing.

164 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Fit gearbox cover and tighten bolts -1- and -2- to 22 Nm.

4.7 Adjusting crown wheel

(Adjusting differential)

Special tools and workshop

equipment required
♦ End measuring plate -
VW 385/17-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Universal dial gauge brack‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

et -VW 387-
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Adjustable measuring lever

-VW 388-
♦ Crown wheel adjusting tool
-VW 521-
♦ Retainer -3177-
♦ Torque wrench -
V.A.G 1331-

4. Adjusting pinion shaft and crown wheel 165

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Dial gauge extension -

VW 382/10-
♦ Thrust plate -VW 402-
♦ Press tool -VW 408 A-
♦ Removal and installing tool
-VW 459/2-
♦ Press tool -VW 472/1-
♦ Oil seal extractor lever -
VW 681-

♦ Thrust piece -2050-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

166 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

♦ Dial gauge , e.g. -VAS 6080-

♦ Dial gauge extension, 30 mm

It is necessary to readjust the crown wheel when the following
components have been renewed:
Gearbox housing, cover for final drive, tapered roller bearings for
differential, differential cage or final drive gear set
Table of adjustments ⇒ page 152
Determining total shim thickness „Stotal“ for shims „S1“ plus
„S2“
(Setting preload of tapered roller bearings for differential)
• Pinion shaft removed

Note

If only the tapered roller bearings for the differential are being re‐
newed, the crown wheel can be removed from the differential
cage. The pinion shaft then does not have to be removed.

– Remove flange shaft oil seals.

– Remove tapered roller bearing outer races for differential and
take out shims ⇒ page 141 .
– Drive outer race for tapered roller bearing (right-side) with
shim „S2“ into gearbox housing. For measurement purposes
use a 1.22 mm thick „S2*“ shim (or 2 shims of 0.61 mm).

Note

♦ For measurement purposes a 1.22 mm thick shim „S2“ is in‐

serted provisionally in gearboxes from 08.98 onwards. This is
referred to in the following as „S2*“. „S2*“ is exchanged with
the final shim „S2“ after determining backlash.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ For gearboxes up to approx. 08.98, insert a 1.20 mm thick
shim „S2*“ (two 0.60 mm shims) provisionally.
♦ Use thrust plate -30 - 205- in place of press tool -VW 472/1-
on gearboxes which have flange shafts without polygon bear‐
ings.

4. Adjusting pinion shaft and crown wheel 167

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Press outer race for tapered roller bearing (left-side) without

shim „S1“ into cover for final drive.

Note

For gearboxes without reinforcements up to approx. 08.98, press

tool -VW 472/1- must be used in place of thrust piece -2050-
⇒ page 147 .

– Insert differential without drive wheel for speedometer sender

-G22- into gearbox housing.
The crown wheel is located on the left side (cover side).
– Fit cover for final drive and tighten 4 bolts to 25 Nm in diagonal
sequence.
– Turn gearbox so that cover for final drive points upwards.
– Turn differential 5 turns in both directions so that the tapered
roller bearings settle.

– Place measuring plate -VW 385/17- on differential.

– Set up measuring tool using 30 mm dial gauge extension
-A-.
– Set dial gauge e.g. -VAS 6080- (3 mm measuring range) to „0“
with 2 mm preload.
• The tip of the dial gauge must be applied to the centre of the
differential.
– Raise differential without turning, read clearance off dial gauge
and note down.
• Measurement in following example: 0.62 mm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

168 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ To lift differential, secure crown wheel adjusting tool -VW

521/4- and -VW 521/12- (for gearboxes with polygon bearing)
on right side of differential (housing side).
♦ Use sleeve -VW 521/8- in place of sleeve -VW 521/12- on
gearboxes which have flange shafts without polygon bearings.
♦ If the measurement has to be repeated, the differential must
again first be turned 5 turns in each direction to settle the ta‐
pered roller bearings. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Formula: „Stotal“ = „S2*“ + measuredwith
value + bearing preload
respect to the correctness of information in this document. Copyright by AUDI AG.

Example:
Example:
Inserted shim(s) „S2*“ 1.22 mm
+ Measured value 0.62 mm
+ Bearing preload (constant value) 0.25 mm
= Total shim thickness „Stotal“ for „S1“ plus „S2“ 2.09 mm

Determining thickness of shim „S1*“

Note

♦ Provisional shim „S1*“ is replaced with final shim „S1“ after

determining backlash.
♦ Total shim thickness "Stotal" remains unchanged.

Formula: „S1*“ = „Stotal“ – „S2*“

Example:
Total shim thickness „Stotal“ for „S1“ plus „S2“ 2.09 mm
- Inserted shim(s) „S2*“ 1.22 mm
= Thickness of shim „S1*“ 0.87 mm

Select correct shims from ⇒ Electronic parts catalogue .

Measuring backlash
(Position of crown wheel in gearbox housing)
• Pinion shaft fitted with shims „S3“ and „S4“.
– Install differential with shims „S1*“ and „S2*“.
– Fit cover for final drive and tighten bolts to 25 Nm.
– Turn differential 5 turns in both directions to settle tapered roll‐
er bearings.

4. Adjusting pinion shaft and crown wheel 169

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

– Secure dial gauge bracket -VW 387- to housing.

– Attach crown wheel adjusting device -VW 521/4- and -VW
521/12- (on gearbox with polygon bearings), or -VW 521/8-
(on gearbox without polygon bearings).
– Fit dial gauge with dial gauge extension -VW 382/10- (6 mm
flat).
– Set measuring lever -VW 388- to dimension „a“ according to
crown wheel ∅:
Dimension „a“ Crown wheel ∅
67 mm 170 mm
72 mm 180 mm
– Measure play between teeth faces (backlash) as follows:
– Turn crown wheel until it makes contact with the face of one
tooth (end of backlash travel).
– Preload dial gauge to 2 mm and set to „0“.
– Turn back crown wheel until it makes contact with opposite
tooth face (backlash).
– Take backlash reading and note down measured value.
– Turn crown wheel through 90° and repeat measurements an‐
other 3 times.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

170 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Note

♦ If the pinion shaft rotates when the differential is turned, fit re‐
tainer -3177- -A- so that the backlash can be measured ex‐
actly.
♦ Loosen the clamp in order to turn the crown wheel.
♦ When inserting the differential, the opening for the differential
bevel gears must then face the pinion shaft.

– If the retainer -3177- has been fitted, install differential turned

through 180° and repeat measuring procedure.
Determining average backlash
– Add the four measured values together and divide by four.
Example:
1st measured value 0.28 mm
+ 2nd measured value 0.30 mm
+ 3rd measured value 0.30 mm
+ 4th measured value 0.28 mm
= Sum of measured values 1.16 mm
• Result: the average backlash is 1.16 mm : 4 = 0.29 mm

Note

If the individual measurements differ by more than 0.06 mm, this

means that by
Protected the installation
copyright. ofprivate
Copying for the crown wheel
or commercial is not
purposes, correct
in part or is not
or in whole,
that the finalunless
permitted drive gear set
authorised itself
by AUDI AG. is
AUDIdefective.
AG does not Check
guarantee the installa‐
or accept any liability
tion; renew the tofinal
with respect drive gear
the correctness set if necessary.
of information in this document. Copyright by AUDI AG.

Determining thickness of shim „S2“

Formula: „S2“ = „S2*“ – backlash + lift

Example:
Inserted shim(s) „S2*“ 1.22 mm
- Average backlash 0.29 mm
+ Lift (desired average value for backlash) 0.15 mm
= Thickness of shim „S2“ 1.08 mm

– Select thickness of required shim(s) from following tables:

Available shims „S2“ up to approx. 08.98

Shim thickness (mm) 1)2)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
• 1) For part numbers, refer to ⇒ Electronic parts catalogue .
• 2)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

4. Adjusting pinion shaft and crown wheel 171

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Available shims „S2“ from 08.98 onwards

Shim thickness (mm) 1)2)

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
• 1) For part numbers, refer to ⇒ Electronic parts catalogue .
• 2)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

Determining thickness of shim „S1“

Formula: „S1“ = „Stotal“ – „S2“

Example:
Total shim thickness „Stotal“ 2.09 mm
for „S1“ plus „S2“
- Thickness of shim „S2“ 1.08 mm
= Thickness of shim „S1“ 1.01 mm

– Select thickness of required shim(s) from following tables:

Available shims „S1“ up to approx. 08.98

Shim thickness (mm) 1)2)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
• 1) For part numbers, refer to ⇒ Electronic parts catalogue .
• 2)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

Available shims „S1“ from 08.98 onwards

Shim thickness (mm) 1)2)

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 unless authorised by AUDI 0.85
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted AG. AUDI AG does not guarantee or accept any liability
0.57 0.73
with respect to the correctness of information in this document. Copyright by AUDI AG.

• 1) For part numbers, refer to ⇒ Electronic parts catalogue .

• 2)The exact shim thickness required can be obtained by us‐
ing the shim tolerance variations. Install two shims if neces‐
sary.

172 Rep. gr.39 - Final drive - differential

 Audi A4 1995 ➤
5-speed manual gearbox 012/01W, front-wheel drive - Edition 01.2012

Checking adjustment
– After installing shims „S1“ and „S2“, turn differential 5 turns in
both directions so that the tapered roller bearings settle.
– Measure backlash four times on circumference.
• Specification: 0.12 ... 0.22 mm

Note

♦ Use sleeve -VW 521/8- in place of sleeve -VW 521/12- on

gearboxes which have flange shafts without polygon bearings.
♦ Adjustment must be repeated if backlash is outside tolerance.
The total shim thickness „Stotal“ must remain unchanged.
♦ The discrepancy between individual measured values must
not exceed 0.06 mm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Adjusting pinion shaft and crown wheel 173