Service

Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive
Edition 12.2010

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.

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 A0059188920

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Calculating ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Servicing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Exploded view - pedal cluster (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Removing and installing clutch pedal switch for engine start F194 . . . . . . . . . . . . . . . . . . 12
1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Exploded view - pedal cluster (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Exploded view - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 18
1.8 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 18
1.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.10 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Exploded view - servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Exploded view - servicing clutch with SAC pressure plate (LuK version) . . . . . . . . . . . . . . 38
3.2 Removing and installing clutch with SAC pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Resetting adjuster ring in SAC clutch pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Servicing gear lever and gear lever bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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
1.4 with respect
Servicing selectorof rod,
to the correctness connecting
information rod Copyright
in this document. and push rodAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
by AUDI
1.5 Removing and installing gear knob with boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1 Removing gearbox - vehicles with 2.5 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Installing gearbox - vehicles with 2.5 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Removing gearbox - vehicles with 2.7 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4 Installing gearbox in vehicles with 2.7 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4 Mounting gearbox on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5 Exploded view - gearbox mounting and tunnel cross member . . . . . . . . . . . . . . . . . . . . . . 92
5.1 Removing and installing gearbox mounting and tunnel cross member . . . . . . . . . . . . . . . . 92
6 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7 Removing and installing reversing light switch F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Renewing oil seal for selector shaft with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 97
9 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Contents i
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

10 Removing and installing selector shaft locking bushes (with gearbox installed in vehicle)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1 Renewing flange shaft oil seals (left and right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Renewing flange shaft oil seal (left-side) with gearbox installed in vehicle . . . . . . . . . . . . 107
1.2 Renewing flange shaft oil seal (right-side) with gearbox installed in vehicle . . . . . . . . . . . . 110
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Removing and installingpermitteddifferential . . . . by
. .AUDI
. . .AG.. . AUDI
. . . AG
. . does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
......... 114
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised
2.2 Dismantling and assembling differential
with respect . . . .of. information
to the correctness . . . . . . in. .this. .document.
. . . . . Copyright
. . . . . .by. AUDI
. . . .AG.......... 114
3 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

ii Contents
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 0A2, front-wheel drive is installed
in the Audi A4 2001 ► and A4 Cabriolet 2003 ► in conjunction with
the V6 TDI engine.
Allocation ⇒ page 1 .
Location on gearbox
♦ Code letters and serial number -arrow 1-
♦ Manual gearbox 0A2 -arrow 2-

Code letters and gearbox serial number -arrow 1-

Example: GHA 0000474
I I
Code letters Gearbox serial number
Additional data are manufacture-related.

Note

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

Manual gearbox 0A2 -arrow 2-

1.1 Code letters, allocation, transmission ra‐

tios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Gear oil specification 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
♦ Correct type of flange shafts with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Correct type of clutch plate and pressure plate

1. Gearbox identification 1
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Manual gearbox 6-speed 0A2 (front-wheel drive)

Code letters FZJ GHA HEN
Manufactured from 06.03 06.03 12.03
to 06.03 12.03 01.05
Allocation Model A4 2001 ► A4 2001 ► A4 2001 ►, A4 Cabrio‐
let 2003 ►
Engine 2.5 ltr. TDI - 120 kW 2.5 ltr. TDI - 120 kW 2.5 ltr. TDI - 120 kW
Ratio Final drive 31 : 8 = 3.875 31 : 8 = 3.875 31 : 8 = 3.875
i = Z2 : Z1 1st gear 32 : 9 = 3.556 32 : 9 = 3.556 32 : 9 = 3.556
2nd gear 40 : 21 = 1.905 40 : 21 = 1.905 40 : 21 = 1.905
3rd gear 36 : 29 = 1.241 36 : 29 = 1.241 36 : 29 = 1.241
4th gear 30 : 34 = 0.882 30 : 34 = 0.882 30 : 34 = 0.882
5th gear 29 : 44 = 0.659 29 : 44 = 0.659 29 : 44 = 0.659
6th gear 29 : 52 = 0.558 29 : 52 = 0.558 29 : 52 = 0.558
Reverse gear 30 : 9 = 3.333 30 : 9 = 3.333 30 : 9 = 3.333
Capacity 3.2 ltr.
Overall ratio iov. in top gear 2.161 2.161 2.161

Manual gearbox 6-speed 0A2 (front-wheel drive)

Code letters HPE HSL HXR
Manufactured from 10.05 12.04 11.05
to 05.06 05.06
Allocation Model A4 2001 ►, A4 Cabrio‐ A4 2001 ►, A4 Cabrio‐ A4 2001 ►
let 2003 ► let 2003 ►
Engine 2.5 ltr. TDI - 120 kW 2.5 ltr. TDI - 120 kW 2.7 ltr. TDI - 132 kW
Ratio Final drive 31 : 8 = 3.875 31 : 8 = 3.875 31 : 8 = 3.875
i = Z2 : Z1 1st gear 32 : 9 = 3.556 32 : 9 = 3.556 32 : 9 = 3.556
2nd gear 40 : 21 = 1.905 40 : 21 = 1.905 40 : 21 = 1.905
3rd gear 36 : 29 = 1.241 36 : 29 = 1.241 36 : 29 = 1.241
4th gear 30 : 34 = 0.882 30 : 34 = 0.882 30 : 34 = 0.882
5th gear 29 : 44 = 0.659 29 : 44 = 0.659 29 : 44 = 0.659
6th gear 29 : 52 = 0.558 29 : 52 = 0.558 29 : 52 = 0.558
Reverse gear 30 : 9 = 3.333 30 : 9 = 3.333 30 : 9 = 3.333
Capacity 3.2 ltr.
Overall ratio iov. in top gear 2.161 2.161 2.161

Manual gearbox 6-speed 0A2 (front-wheel drive)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Code letters JME 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.
Manufactured from 06.06
to
Allocation Model A4 2001 ►
Engine 2.7 ltr. TDI - 132 kW
Ratio Final drive 29 : 8 = 3.625
i = Z2 : Z1 1st gear 32 : 9 = 3.556
2nd gear 40 : 21 = 1.905
3rd gear 36 : 29 = 1.241

2 Rep. gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Manual gearbox 6-speed 0A2 (front-wheel drive)

Code letters JME
4th gear 30 : 34 = 0.882
5th gear 29 : 44 = 0.659
6th gear 29 : 52 = 0.558
Reverse gear 30 : 9 = 3.333
Capacity 3.2 ltr.
Overall ratio iov. in top gear 2.022

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 3
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

2 Transmission layout
Identification
-Arrows- point in direction of travel

1 - Engine
2 - Clutch
3 - Input shaft
4 - Manual gearbox
5 - Pinion shaft (output shaft)
6 - 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.

Ratio
-Arrows- point in direction of travel

4 Rep. gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

2.1 Calculating ratio „i“

Transmission ratio
Transmission ratio = No. of teeth on driv‐ : No. of teeth on
en gear drive gear
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Ratios permitted unless authorised by AUDIFormula
AG. AUDI AG does not guarantee or accept any liability

iG = Gear ratio ZG2 : ZG1

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

iA = Axle ratio ZA2 : ZA1

iov = Overall ratio iG x iA

Example:
6th gear Final drive
Drive gear ZG1 = 52 ZA1 = 8
Driven gear ZG2 = 29 ZA2 = 31

Calculations:
iG = 29 : 52 = 0.558
iA = 31 : 8 = 3.875
iov = 0.558 x 3.875 = 2.161

2. Transmission layout 5
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

3 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.
To avoid unnecessary repetition, a number of generally applica‐
ble instructions for the various repair procedures are summarised
here under the heading „Components“ ⇒ page 6 . They apply
to the work described in this Manual.

3.1 Components
Gearbox
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ When installing mounting brackets as well as other waxed
components, the contact surfaces must be cleaned. The con‐
tact surfaces must be free of wax and grease.
♦ Allocate bolts and other components according to gearbox
code letters, refer to ⇒ Electronic parts catalogue .
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 95 .
♦ Capacities and specifications ⇒ page 1
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
Sealants
♦ Thoroughly clean housing contact surfaces before applying
sealing paste.
♦ 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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ After renewing gaskets and oil seals, check and, if necessary,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
top up oil level in gearbox ⇒ page 95 . with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Rep. gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Locking elements

♦ 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-.

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. General repair instructions 7

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

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 parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ 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.
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
⇒ „1.7 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 18 ).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The clutch system should be bled at the same intervals
permitted unless as the by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
brake system ⇒ Maintenance ; Booklet 45 . with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ On vehicles with SAC pressure plate an adjuster ring has to
be reset when only the clutch plate is renewed ⇒ page 43 .
♦ Note assembly instructions for SAC pressure plate
⇒ page 41 .
♦ 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.
♦ Only blow out dual-mass flywheel with compressed air.

3.2 Special tools

For a complete list of special tools used in this Workshop Manual
⇒ "Special tools, Workshop equipment"

3.3 Contact corrosion!

Contact corrosion can occur if unsuitable fasteners are used on
the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.

8 Rep. gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.

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. General repair instructions 9

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

30 – Clutch
1 Servicing clutch mechanism

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

Note

♦ Lubricate all bearings and contact surfaces withProtected

polycarbamide grease
by copyright. Copying -G 052
for private 142 A2-purposes,
or commercial . in part or in whole, is not

♦ Before working on pedal cluster, remove storage compartment on driver's side ⇒in this
General
document.body repairs,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information Copyright by AUDI AG.
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 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.

I - Pedal cluster (LHD vehicles)

♦ ⇒ „1.1 Exploded view - ped‐
al cluster (LHD vehicles)“,
page 11
♦ ⇒ „1.2 Removing and instal‐
ling clutch pedal switch F36
“, page 12
♦ ⇒ „1.3 Removing and instal‐
ling clutch pedal switch for
engine start F194 “,
page 12
♦ ⇒ „1.4 Removing and instal‐
ling over-centre spring“,
page 13
II - Pedal cluster (RHD vehi‐
cles)
♦ ⇒ „1.5 Exploded view - ped‐
al cluster (RHD vehicles)“,
page 14
III - Clutch hydraulics
♦ ⇒ „1.6 Exploded view - hy‐
draulic system“, page 16
♦ ⇒ „1.7 Notes on removing
and installing clutch master
cylinder and slave cylin‐
der“, page 18
♦ ⇒ „1.8 Function check for
clutch master cylinder and
slave cylinder“, page 18
♦ ⇒ „1.9 Removing and instal‐
ling clutch master cylinder“,
page 19

10 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ ⇒ „1.10 Bleeding clutch

system“, page 27

1.1 Exploded view - pedal cluster (LHD vehicles)

1 - Mounting bracket
❑ Removing and installing
⇒ page 19 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Pivot pin for clutch and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

3 - Retaining clip
4 - Hexagon socket head bolt
❑ 25 Nm
5 - Brake pedal
❑ Maintenance-free bear‐
ing, do not grease
6 - Clutch pedal switch -F36-
❑ May only be installed
once; must always be
renewed if removed
❑ Removing and installing
⇒ page 12
7 - Hexagon socket head bolt
❑ 5 Nm
❑ Secures clutch and
brake pedal pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 19
9 - Retaining clip
10 - Retaining clip
❑ Removing and installing
⇒ Item 9 (page 16)
11 - Hexagon socket head bolt
❑ 20 Nm
12 - Clutch master cylinder
❑ Removing and installing ⇒ page 19
❑ Seal -arrow- must not be removed
13 - Over-centre spring
❑ Black side points towards clutch pedal
❑ Removing and installing ⇒ page 13
❑ For correct version, refer to ⇒ Electronic parts catalogue
14 - Clutch pedal switch for engine start -F194-
❑ Only for USA
❑ Engine can only be started when clutch is fully depressed ( clutch pedal switch for engine start activated ).
❑ May only be installed once; must always be renewed if removed
❑ Removing and installing ⇒ page 12
15 - TORX bolt
❑ 25 Nm

1. Servicing clutch mechanism 11

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

❑ For securing brake master cylinder/brake servo to mounting bracket

1.2 Removing and installing clutch pedal

switch -F36-

Note

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

a firm fit.

Removing
– Remove storage compartment on driver's side ⇒ General
body repairs,
Protected byinterior; Rep. for
copyright. Copying gr.private
68 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
– Unplug with
connector -1-correctness
respect to the from clutch pedal
of information switch
in this -F36-
document. . by AUDI AG.
Copyright

• The clutch pedal -3- is in the normal position (i.e. not pressed
down). The plunger -arrow- of the clutch pedal switch should
then rest against the clutch pedal.
– Release clutch pedal switch -F36- -2- by turning 45° anti-
clockwise and take out of guide.
Installing

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

– Pull out plunger -arrow- all the way before installing clutch
pedal switch -F36- .

• The clutch pedal should be in the normal position (i.e. not

pressed down).
– Guide clutch pedal switch -F36- through mounting hole, press
plunger against clutch pedal and secure switch by turning 45°
clockwise.
– Plug in connector for clutch pedal switch -F36- .
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

1.3 Removing and installing clutch pedal

switch for engine start -F194-

Note

To ensure a secure fit, the clutch pedal switch for engine start -
F194- must not be installed more than once.

12 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .
– Detach electrical connector -3- on clutch pedal switch for en‐
gine start -F194- .
– Press clutch pedal -1- all the way down and hold it in this po‐
sition.
– At the same time, release clutch pedal switch for engine start
-F194- -2- by turning it 45° in the direction indicated -arrow-
and pull it out of the guide.

Installing
– Pull out plunger -arrow- all the way before installing clutch
pedal switch .

– When installing clutch pedal switch for engine start -F194- ,

press clutch pedal -1- all the way down -arrow A-. Hold clutch
pedal in this position.
– Guide clutch pedal switch for engine start -F194- -2- through
opening in retainer, and at the same time push plunger
Protected against
by copyright. Copying for private or commercial purposes, in part or in whole, is not
clutch pedal and secure switch by turning it 45° in theunless
permitted direction
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
indicated -arrow B-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Attach electrical connector -3- on clutch pedal switch for en‐

gine start -F194- .
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

1.4 Removing and installing over-centre

spring
Special tools and workshop equipment required

1. Servicing clutch mechanism 13

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Assembly clip -T40025-

Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .
– Compress over-centre spring with clutch pedal, at the same
time pressing on assembly clip -T40025- .
– Move clutch pedal to rest position and take out over-centre
spring together with assembly clip -T40025- downwards.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installing 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 clutch pedal into the passenger compartment.
• Installation position of over-centre spring: black side of over-
centre spring faces clutch pedal.
– Install over-centre spring with assembly clip -T40025- , oper‐
ate clutch pedal and remove assembly clip .
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

1.5 Exploded view - pedal cluster (RHD vehicles)

14 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1 - Mounting bracket
❑ Removing and installing
⇒ page 19
2 - Washer
3 - Brake pedal
❑ Maintenance-free bear‐
ing, do not grease
4 - Hexagon socket head bolt
❑ 5 Nm
❑ For securing the bearing
sleeve
5 - Hexagon socket head bolt
❑ 25 Nm
6 - Clutch pedal switch -F36-
❑ Removing and installing
⇒ page 12
❑ May only be installed
once; must always be
renewed if removed
7 - Bearing sleeve
❑ Check for freedom of
movement in clutch
pedal
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Clutch pedal 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.
❑ Removing and installing
⇒ page 19
9 - Retaining clip
❑ Removing and installing
⇒ Item 9 (page 16)
10 - Hexagon socket head bolt
❑ 20 Nm
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 19
❑ Seal -arrow- must not be removed
12 - Over-centre spring
❑ Removing and installing ⇒ page 13
❑ For correct version, refer to ⇒ Electronic parts catalogue
13 - Bolt
❑ 22 Nm
❑ Self-locking
❑ Renew
14 - Lever
❑ Pin only fits in one position
15 - Washer
16 - Bearing
❑ For over-centre spring
17 - TORX bolt
❑ 25 Nm
❑ For securing brake master cylinder/brake servo to mounting bracket

1. Servicing clutch mechanism 15

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

18 - Bolt
❑ 25 Nm

1.6 Exploded view - hydraulic system

1 - Brake fluid reservoir

2 - Supply hose
❑ For clutch master cylin‐
der
3 - Pipe/hose assembly
❑ For plug-in connections
on clutch master cylin‐
der and slave cylinder
❑ Disconnecting from
clutch master cylinder
and installing
⇒ page 23
❑ Disconnecting from
clutch slave cylinder
⇒ page 18
❑ Allocation for LHD and
RHD vehicles ⇒ Elec‐
tronic parts catalogue
4 - Grommet
5 - Mounting bracket
6 - Clutch pedal
7 - Clutch master cylinder
❑ 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 with19
respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Do not remove clip
-arrow A- or seal
-arrow B-.
❑ To remove pipe/hose
assembly, pull out clip
-arrow A-, but only as far
as limit stop
⇒ page 23 .
8 - Hexagon socket head bolt
❑ 20 Nm
9 - Retaining clip
❑ Only renew when clutch master cylinder has been removed
❑ Lever off to remove ⇒ page 17
❑ Push in to install ⇒ page 17
10 - Gearbox
11 - Clutch slave cylinder
❑ Do not operate clutch pedal after slave cylinder has been removed
❑ Removing and installing ⇒ page 33
❑ After working on hydraulic clutch mechanism, bleed clutch system ⇒ page 27
❑ Disconnecting pipe/hose assembly ⇒ page 18
❑ Do not allow brake fluid to come into contact with gearbox.

16 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

12 - Bleeder valve
❑ Tighten to 4.5 Nm
❑ Follow correct procedure when bleeding ⇒ page 27
❑ If bleeder valve has broken off, it can be removed with 3 mm Allen key
13 - Dust cap
14 - Clip
❑ To remove pipe, pull out clip as far as limit stop ⇒ page 18
15 - Bracket
❑ For pipe/hose assembly
❑ Attached to gearbox together with slave cylinder
16 - Hexagon socket head bolt
❑ 25 Nm
❑ Clutch slave cylinder to gearbox
❑ Self-locking
❑ Renew
17 - Retaining clip
18 - Seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

19 - Securing bolt
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 brake fluid reservoir

Levering retaining clip -A- off in direction of arrow

Pressing master cylinder operating rod into retaining clip -A- (in
direction of -arrow-)

1. Servicing clutch mechanism 17

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Disconnecting clutch slave cylinder from pipe/hose assembly

Removing
– To remove pipe/hose assembly, use a screwdriver to lever off
clip -A- as far as the stop. Only then can the pipe/hose as‐
sembly be pulled out.
Installing
– Press retaining clip -A- in as far as it will go.
– Insert pipe/hose assembly -B- in clutch slave cylinder and
make sure that it engages audibly.
– Pull on pipe/hose assembly to check it is secure.

1.7 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
⇒ „1.8 Function check for clutch master cylinder and slave
cylinder“, page 18 .
♦ 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.

1.8 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:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ First check the over-centre
permitted spring
unless authorised / clutch
by AUDI AG. AUDI pedal
AG does switch for or accept any liability
not guarantee
noise. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ 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.

18 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ The self-bleeding function of the clutch system can be im‐

paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
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.
♦ Bleed clutch system ⇒ page 27 .
High pedal force:
♦ Clutch plate is worn (except for SAC)
♦ Mechanically defective pressure plate/ clutch plate
⇒ page 38
Pedal forces:
Conventional clutch: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

- Clutch lining when new: approx. 115 N

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.

- Clutch lining at wear limit: approx. 160 N

SAC clutch:
- approx. 140 N for complete service life of the clutch
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 27 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 ⇒ Engine, mechanics; Rep.
gr. 13 .
♦ Foreign body in clutch system
♦ Mechanically defective pressure plate/clutch plate
⇒ page 38 .
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate).

1.9 Removing and installing clutch master

cylinder
Special tools and workshop equipment required

1. Servicing clutch mechanism 19

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Hose clamps, up to 25 mm -3094-

♦ Spark plug connector pliers -V.A.G 1922-

Removing

Note

♦ If you suspect a defective clutch master cylinder, perform

function test prior to renewing
⇒ „1.7 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 18 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ When performing work
permitted unless in thebyfootwell,
authorised putAG
AUDI AG. AUDI cloths onguarantee
does not the carpet
or accept any liability
to protect itwith
from possible
respect brakeoffluid
to the correctness spills.
information in this document. Copyright by AUDI AG.

Caution

♦ Follow steps required when disconnecting battery ⇒ Elec‐

trical system; Rep. gr. 27 .
♦ 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.

20 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Pull off rubber seal on plenum chamber in

-direction of arrow-.
– Detach cover -1- from plenum chamber.
– With the ignition switched off, disconnect battery earth strap
⇒ Electrical system; Rep. gr. 27 .

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.

– Use screwdriver to pry off the two caps -3-.

– Unscrew nuts -4- and detach the two wiper arms -2-.
– Pull off clips -1- and detach cowl panel grille -5-.

Take the electronics box out of the plenum chamber as follows:

– Unscrew bolts -arrows- and take off the cover.

– Use screwdriver to carefully pry off retaining strap -arrow-.

1. Servicing clutch mechanism 21

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Release catches -arrows- and unplug connectors -1- and -2-

at engine control unit.

– Unplug connectors -2- at connector console.

– Unscrew electrical wiring connection -1-.

– Release catches -arrows- and lift auxiliary relay carrier out of

electronics box.
– Pull engine wiring harness together with rubber grommet out
through opening in electronics box.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove nuts -arrows- and lift out
permitted electronics
unless boxAG.
authorised by AUDI -1-.
AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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.

22 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– 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 connection
pipe for supply hose.
– Lever out retaining clip -C- using a screwdriver and pull pipe/
hose assembly -B- out slightly.

– Unscrew bolt for brake fluid reservoir -1- and unplug connector
for brake fluid level warning contact downwards.

Note

The brake fluid reservoir does not have to be removed.

– Remove vacuum pipe leading to brake servo -1-.

– Remove the two TORX bolts -arrows-.

Note

♦ To simplify the illustration, the brake fluid reservoir has not

been included.
♦ The brake fluid reservoir must be moved slightly to the side in
order to unscrew the upper TORX bolt.

– Remove storage compartment on driver's side ⇒ General

body repairs, interior; Rep. gr. 68 .
– Remove over-centre spring ⇒ page 13 .

– Disconnect brake pedal from brake servo ⇒ Brake system;

Rep. gr. 47 .

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 23

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Disconnect steering column from steering box -arrow A- ⇒

Running gear, front-wheel drive and four-wheel drive; Rep. gr.
48 .
– Unplug connectors from clutch pedal switch -F 36- -1-, brake
light switch -2- and accelerator pedal module -3-.
– If fitted, unplug connector from clutch pedal switch for engine
start -F194- .
– Unscrew securing bolt for mounting bracket -arrow B- and re‐
move entire pedal cluster.

Release master cylinder operating rod from clutch pedal as fol‐

lows:

Note

♦ When releasing the operating rod, make sure that clutch pedal
does not collide with mounting bracket for clutch pedal switch
-arrow-. The mounting bracket could otherwise break off.
♦ To ensure a secure fit in the pedal cluster, the clutch pedal
switch -F36- ⇒ Item 6 (page 11) and clutch pedal switch for
engine start -F194- ⇒ Item 14 (page 11) may only be installed
once.

– Apply spark plug connector pliers -V.A.G 1922- in clutch pedal

recesses, press on sides of retaining clip ⇒ Item 9 (page 16)
and detach clutch pedal from clutch master cylinder.

– Detach retaining clip -1- and remove clutch pedal -2-.

– Unscrew bolts -3- and remove clutch master 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.

24 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Installing
Installation is carried out in reverse sequence; note the following:
– Fit clutch master cylinder -4- and tighten bolts -3- to 20 Nm.

– Insert retaining clip -1- in clutch pedal.

– Lock clutch pedal in position by pressing in
-direction of arrow-. Make sure retaining clip -1- engages cor‐
rectly in clutch pedal.

A second mechanic is required for the next step.

– Insert entire pedal cluster and tighten bolt -1- by hand. The
second mechanic should guide pipe/hose assembly into clutch
master cylinder from plenum chamber.

– Tighten bolts for brake servo -arrows- to 25 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing clutch mechanism 25

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Press in retaining clip -C- as far as it will go.

– Insert pipe/hose assembly -B- in clutch master cylinder and
make sure that it engages audibly.
– Fit rubber grommet -D- onto connecting pipe for supply hose
-A- at bulkhead.
– Push supply hose -A- from brake fluid reservoir on as far as it
will go.
– Remove hose clamp -3094- .

– Screw in securing bolt -1- for brake fluid reservoir and attach
connector at brake fluid level warning contact .

– Tighten hexagon socket head bolt -arrow B- for securing pedal

cluster to dash panel carrier to 25 Nm.
– Plug in connectors -1-, -2- and -3-.
– If fitted, attach connector for clutch pedal switch for engine
start -F194- .
– Connect brake pedal to brake servo ⇒ Brake system; Rep.
gr. 47 .
– Secure steering column to steering box -arrow A- ⇒ Running
gear, front-wheel drive and four-wheel drive; Rep. gr. 48 .
– Install over-centre spring ⇒ page 14 .
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 storage compartment on driver's
with side
respect⇒ General
to the body
correctness of information in this document. Copyright by AUDI AG.
repairs, interior; Rep. gr. 68 .
– Bleed clutch system ⇒ page 27 .

– Insert electronics box and tighten nuts -arrows- to 4 Nm.

– Route engine wiring harness and plug in connector in con‐
nector console.
– Install engine control unit ⇒ Rep. gr. 23 .
– If applicable, install auxiliary relay carrier and auxiliary fuse
carrier ⇒ Electrical system; Rep. gr. 97 .
– Press on cover (hand-tight) and tighten bolts in diagonal se‐
quence to 4 Nm.
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. gr. 27 .

26 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1.10 Bleeding clutch system

Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-

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

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 ⇒ Maintenance ; Booklet 8E .

– Connect brake filling and bleeding equipment -VAS 5234- , but

do not switch on at this stage ⇒ Brake system; Rep. gr. 47 ;
Bleeding brake system .
– If fitted, remove noise insulation beneath gearbox.
– Remove noise insulation for drive shaft from left wheel 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.

1. Servicing clutch mechanism 27

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– 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 operation.

– Close bleeder valve.

– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
– Disconnect bleeder hose and fit protective cap.
– Screw heat shield for drive shaft (left-side) onto gearbox.
– Install noise insulation below gearbox.
Tightening torques
Component Nm
Bleeder valve 4.5
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Heat shield for drive shaft to gearbox 23
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.

28 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

2 Exploded view - servicing clutch release mechanism

Special tools and workshop

equipment required
♦ Thrust plate -VW 402-
♦ Press tool -VW 412-
♦ Press tool -VW 454-
♦ Torque wrench -V.A.G
1331-
♦ -1- Internal puller -Kukko
21/5-
♦ -4- Counter-support -Kukko
22/1-
♦ Sealing grease -G 052 128
A1-
♦ Adhesive -
AMV 195 KD1 01-
♦ Copper grease (commer‐
cially available)
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. Exploded view - servicing clutch release mechanism 29

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1 - Clutch slave cylinder

❑ Removing and installing
⇒ page 33
❑ Do not operate clutch
pedal after slave cylin‐
der has been removed
❑ When installing, push in
until the securing bolt
⇒ Item 2 (page 30) can
be fitted
❑ Bleeding clutch system
⇒ page 27
❑ Tighten bleeder valve to
4.5 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Hexagon socket head bolt 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.
❑ 23 Nm
❑ Clutch slave cylinder to
gearbox
❑ Self-locking
❑ Always renew
3 - Bracket
❑ For pipe/hose assembly
❑ Bolt to gearbox with
clutch slave cylinder
4 - Plunger
❑ Lubricate end of plunger
with copper grease
(commercially availa‐
ble)
5 - O-ring
❑ Always renew
⇒ page 32
❑ Lubricate with gear oil
before installing
6 - Oil seal
❑ For input shaft
❑ Pull out of guide sleeve ⇒ Item 7 (page 30) ⇒ page 33 .
❑ Installation depth ⇒ page 33
❑ Press into guide sleeve ⇒ Item 7 (page 30) ⇒ page 33 .
❑ Pack space between sealing lip and dust lip half full with sealing grease -G 052 128 A1-
7 - Guide sleeve
❑ Removing and installing ⇒ page 32
❑ Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal
8 - Clutch release lever
❑ Removing and installing ⇒ page 31
❑ Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease
(commercially available).
9 - Release bearing
❑ Do not wash out; wipe clean only
❑ Renew bearing if noisy
❑ Servicing release bearing with glued plastic ring ⇒ page 31
❑ Checking release bearing with mechanically attached plastic ring ⇒ page 32
❑ Renew if groove worn on plastic ring is too deep ⇒ page 32

30 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

❑ Retainer lugs on release bearing must engage in release lever

10 - Bolt
❑ 24 Nm
❑ Self-locking
❑ Before installing bolt, clean thread with wire brush and then apply locking fluid -AMV 185 101 A1-
11 - Leaf spring
12 - Bolt
❑ 24 Nm
❑ Self-locking
❑ Before installing bolt, clean thread with wire brush and then apply locking fluid -AMV 185 101 A1-
13 - Retaining piece
❑ For guide sleeve
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ page 32 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 - Intermediate piece
❑ Renew if damaged
15 - Gearbox

Removing and installing clutch release lever

Removing
– Slacken off bolt -1- and remove leaf spring -2-.
– Remove clutch release lever -3- with release bearing.
– Disengage retaining tabs of release bearing at release lever.
Installing
– Before installing clutch release lever, apply a thin coat of cop‐
per grease (commercially available) to contact surface for
plunger of clutch slave cylinder.
– Fit clutch release lever -3- with release bearing onto guide
sleeve.
– Insert leaf spring -2-.
– Clean thread of bolt -1- with a wire brush. Then insert bolt
-1- with locking fluid -AMV 185 101 A1- and tighten to 24 Nm.

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.
♦ The release bearing must be renewed if the groove worn on
the plastic ring is deeper than 0.8 mm.

2. Exploded view - servicing clutch release mechanism 31

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Checking release bearing with mechanically attached plastic ring

Identification: retaining tabs around plastic ring -arrows-.

♦ 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 -1- is deeper than 0.8 mm.

Removing and installing guide sleeve

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
– Unscrew bolts -arrows- and
with respect to removeofretaining
the correctness information inpiece -1-. Copyright by AUDI AG.
this document.

– Fit a thin insulating hose or shrink hose tightly over splines of

input shaft.
– Pull guide sleeve -2- out of gearbox housing.
Installing
– Renew O-ring in gearbox housing ⇒ page 32 .
• A thin insulating hose or shrink hose is fitted tightly onto input
shaft splines.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Coat outer circumference of guide sleeve with gear oil.
– Push guide sleeve -2- over input shaft and into gearbox hous‐
ing.
– Remove insulating hose/shrink hose.
– Fit retaining piece -1-.
– Clean threads of bolts -arrows- with a wire brush. Then insert
bolts with locking fluid -AMV 185 101 A1- and tighten to 24
Nm.

Renew O-ring
– Pry out O-ring -arrow- using a small screwdriver.
– Lubricate new O-ring with gear oil before installing.

32 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Pulling oil seal for input shaft out of guide sleeve

A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 30 ... 37 mm , e.g. -Kukko 21/5-

Installation depth - oil seal for input shaft

Dimension x = 7.75 mm ± 0.5 mm

Pressing oil seal for input shaft into guide sleeve

– Lightly lubricate outer circumference of oil seal with gear oil.
– Press in oil seal for input shaft
⇒ Fig. “„Installation depth - oil seal for input shaft““ , page 33 .
Make sure oil seal remains straight.
• The open side of the oil seal faces towards press tool -VW
454- .
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .

2.1 Removing and installing clutch slave

cylinder
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Lithium grease -G 052 150 permitted
A2- 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.
♦ Copper grease (commercially available)

2. Exploded view - servicing clutch release mechanism 33

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Removing

Note

♦ If you suspect a defective clutch master cylinder, perform

function test prior to renewing
⇒ „1.7 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 18 .
♦ 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
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.

Caution

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, loosen quick-release fasteners -2- and -3- and remove

rear noise insulation -B-.
– Loosen bolts/quick-release fasteners -1- and -2- and remove
front noise insulation -A-.

– Remove noise insulation from wheel housing (left-side)

-arrows-.

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– Unbolt drive shaft (left-side) -1- from flange shaft and move to
front, making sure you do not damage surface protection.
– Remove front exhaust pipe with catalytic converter ⇒ Engine,
mechanics; Rep. gr. 26 .

34 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– 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.

– To remove pipe/hose assembly, use a screwdriver to lever off

clip -A- as far as the stop. Only then can the pipe/hose as‐
sembly be pulled out.
Installing
Installation is carried out in reverse sequence; note the following:
♦ Do not allow brake fluid to come into contact with the gearbox.
If necessary, clean the gearbox housing.
♦ For easier installation engage 6th gear before fitting slave cyl‐
inder.
♦ When installing, press in slave cylinder so that securing bolt
can be fitted easily.
♦ Renew securing bolt for slave cylinder.
– Using copper grease (commercially available), lightly lubricate
surface where plunger and clutch release lever make contact.

– Before inserting slave cylinder in gearbox housing, lubricate

area -a- of sleeve with lithium grease -G 052 150 A2- .

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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.

2. Exploded view - servicing clutch release mechanism 35

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Attach bracket -3- for pipe/hose assembly -1- to slave cylinder

-4-.

– 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 30)

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-.

Caution

♦ After installing the slave cylinder carefully press the clutch

pedal.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If you permitted
feel anunless
unusually
authorisedstrong point
by AUDI AG. AUDIofAGresistance when
does not guarantee or accept any liability
depressing the clutch
with respect pedal,ofyou
to the correctness mustinnot
information press itCopyright
this document. down by AUDI AG.
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.

36 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– To connect pipe/hose assembly -B- to slave cylinder, press in

retaining clip -A- as far as it will go.
– Insert pipe/hose assembly -B- in slave cylinder so that it en‐
gages audibly.
– Pull on pipe/hose assembly to check it is secure.
– Bleed clutch system ⇒ page 27 .
– Install front exhaust pipe with catalytic converter and align ex‐
haust system so it is free of stress ⇒ Engine, mechanics; Rep.
gr. 26 .
– Bolt drive shaft (left-side) to flange shaft ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 40
– Screw heat shield for drive shaft (left-side) onto gearbox.
Tightening torques
Component Nm
Heat shield for drive shaft 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.

2. Exploded view - servicing clutch release mechanism 37

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

3 Servicing clutch
⇒ „3.1 Exploded view - servicing clutch with SAC pressure plate
(LuK version)“, page 38
⇒ „3.2 Removing and installing clutch with SAC pressure plate“,
page 41
⇒ „3.3 Resetting adjuster ring in SAC clutch pressure plate“, page
43

Note

♦ Refer to general repair instructions ⇒ page 6 .

♦ Observe the notes on removing and installing the clutch mas‐
ter cylinder and slave cylinder ⇒ page 18 .
♦ „SAC“ stands for „Self-Adjusting Clutch“.
♦ On vehicles with SAC pressure plate (self-adjusting clutch) an
adjuster ring has to be reset when only the clutch plate is re‐
newed ⇒ page 43 .
♦ To avoid damaging SAC pressure plate when removing and
installing, observe assembly instructions for SAC pressure
plate ⇒ page 41 .
♦ Check that SAC pressure plate is not distorted ⇒ page 41 .
♦ Renew clutch plate and pressure plate if riveted fastening is
damaged or loose. 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

♦ Select the correct clutch plate and pressure plate according to

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

engine code ⇒ Electronic parts catalogue .

♦ To avoid damaging dual-mass flywheel during removal,
please observe instructions for removal ⇒ page 41 .
♦ 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.
♦ Clutch 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.
♦ Only blow out dual-mass flywheel with compressed air.
♦ 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.

3.1 Exploded view - servicing clutch with SAC pressure plate (LuK version)

38 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1 - Dual-mass flywheel
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Observe instructions for
removal ⇒ page 41
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13
2 - Needle bearing
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13
3 - Bolt
❑ For flywheel
❑ Renew
❑ Tightening torque for
bolt length 22.5 mm:
60 Nm + 90° further
❑ Tightening torque for
bolt length 43 mm:
60 Nm + 180° further
❑ Observe instructions for
removal ⇒ page 41
4 - Clutch plate
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
❑ Installation position:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Clutch lining
permitted must
unless makeby AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
full contact withto flywheel
with respect the correctness of information in this document. Copyright by AUDI AG.

❑ The marking „Getriebeseite“ (gearbox side), if provided, faces towards pressure plate/gearbox
❑ Coil springs (damper assembly) point towards pressure plate and gearbox
❑ Centralising ⇒ page 42
❑ Lightly grease splines ⇒ page 38
5 - SAC pressure plate
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Observe assembly instructions ⇒ page 41 when removing and installing
❑ Resetting adjuster ring ⇒ page 43
❑ Checking ends of diaphragm spring ⇒ page 40
❑ Checking pressure plate for distortion ⇒ page 41
❑ Checking springs and riveting ⇒ page 40
6 - Bolt
Vehicles with 2.5 ltr. TDI engine
❑ Tightening torque = 22 Nm
Vehicles with 2.7 ltr. TDI engine
❑ Tightening torque = 22 Nm + 90°
❑ Always renew

3. Servicing clutch 39
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Continued for all vehicles:

❑ Observe assembly instructions ⇒ page 41 for loosening or tightening

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
missible.

Note

Important: When performing repairs, always match up pressure

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

Checking springs and riveting

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew pressure plate if springs are broken or badly bent
-arrow B-.

– Check that riveting -arrows B- is secure at all springs

-arrows A-.
• Renew pressure plate if rivets -arrows B- are loose.

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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.

40 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Checking SAC pressure plate for distortion, cracks and burning

A - Straightedge
B - Feeler gauge
• Pressure plate distortion up to 0.8 mm is permissible

Removing dual-mass flywheel

Caution

Do not use an impact wrench or pneumatic wrench to remove

bolts -B-: this would severely damage the dual-mass flywheel.
Bolts -B- must always be removed by hand.

– Rotate flywheel -A- so that bolts -B- are aligned centrally be‐
hind the holes -arrows-.
– When unscrewing bolts -B-, make sure the bolt heads do not
contact the flywheel -arrows- because this would damage the
flywheel when the bolts are turned further.
– Removing and installing dual-mass flywheel ⇒ Engine, me‐
chanics; Rep. gr. 13

3.2 Removing and installing clutch with SAC

pressure plate
Special tools and workshop equipment required
♦ Counterhold tool -10 - 201-

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. Servicing clutch 41
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Centring mandrel -3176-

♦ Grease for clutch plate splines -G 000 100-

Removing
– Attach counterhold tool -10 - 201- 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 six bolts consecutively in clockwise direction and in
steps of 90° (1/4 turn) until the pressure plate is released.
Installing

Note

♦ Before you re-install the SAC pressure plate check that it is

not distorted ⇒ page 41 .
♦ When only the clutch plate is renewed, the adjuster ring in the
SAC pressure plate has to be reset before assembly
⇒ page 43 .

• Installation position of clutch plate: coil springs (damper as‐

sembly)Protected
or marking „Getriebeseite“ point towards pressure
plate and gearbox.
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.
– Use centring mandrel -3176- to centralise clutch plate.
– Re-position counterhold tool -10 - 201- to tighten bolts.
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 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Tighten all six bolts consecutively in clockwise direction and
in steps of 90° (1/4 turn) until the housing makes contact with
flywheel.
– Tighten all 6 bolts to final torque consecutively in clockwise
direction. Tightening torque ⇒ Item 6 (page 39)

42 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

3.3 Resetting adjuster ring in SAC clutch

pressure plate

Note

♦ When fitting a new clutch plate in conjunction with a used SAC

pressure plate, the adjuster ring in the pressure plate has to
be reset by turning it back as far as it will go. If you do not reset
the adjuster ring in the pressure plate, the SAC pressure plate
will operate with reduced clamping force, which will cause ex‐
cessive wear, especially of the clutch plate (clutch will then
slip).
♦ If the clutch plate is not renewed, it is not necessary to reset
the adjuster ring.
♦ New SAC pressure plates are pre-set accordingly, and do not
have to be reset.

Special tools and workshop equipment required

♦ Press tool -VW 412-

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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.

♦ Thrust pad -3062-

Procedure
– Insert 3 bolts for securing pressure plate -A- into mounting
holes in pressure plate at 120° intervals (1/3 turn), as shown
in illustration.
– Screw 3 nuts -B- -M8- onto bolts -A- and tighten nuts.

3. Servicing clutch 43
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Place the SAC pressure plate onto the press so that only the
3 bolt heads -arrows- make contact.
– Position thrust pad -3062- in the centre of the pressure plate.

Caution

Do not use force when performing the following steps, as this

could cause the forks on the adjuster ring to break off.

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.

– Apply two screwdrivers to the forks on the adjuster ring. Use

the press to apply pressure to the pressure plate until it is just
possible to move the adjuster ring.

44 Rep. gr.30 - Clutch

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Using the two screwdrivers, turn back the adjuster ring evenly
in -direction of arrows- until it reaches the stop.
– Hold the adjuster ring against the stop and relieve the pressure
applied by the press so that the adjuster ring is held in this
position.

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. Servicing clutch 45
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

34 – Controls, housing
1 Servicing selector mechanism
♦ ⇒ „1.1 Installation position of selector mechanism“,
page 46
♦ ⇒ „1.2 Exploded view - selector mechanism“, page 48
♦ ⇒ „1.3 Servicing gear lever and gear lever bearing“,
page 49
♦ ⇒ „1.4 Servicing selector rod, connecting rod and push rod“,
page 50
♦ ⇒ „1.5 Removing and installing gear knob with boot“,
page 51
♦ ⇒ „1.6 Removing and installing selector mechanism“,
page 52
♦ ⇒ „1.7 Adjusting selector mechanism“, page 57

1.1 Installation position of selector mechanism

-Arrow A- gear selection movement
-Arrow B- gate selection movement

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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.

46 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1 - Selector rod
2 - Push rod
3 - Connecting rod
4 - Gearbox selector lever

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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.

1. Servicing selector mechanism 47

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1.2 Exploded view - selector mechanism

I - Servicing gear lever and

gear lever bearing
⇒ page 49
II - Servicing selector rod, con‐
necting rod and push rod
⇒ page 50

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.

48 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

1.3 Servicing gear lever and gear lever bearing

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
5 - Washer
❑ Lip points towards ball
guide
⇒ Item 3 (page 49)
6 - Circlip
❑ Take out before remov‐
ing ball
7 - Spring
8 - Spacer sleeve
9 - Washer
❑ Not fitted on all versions
10 - Circlip
❑ Always renew
11 - Noise insulation
❑ -Arrow- marked on
noise insulation points
in direction of travel
12 - Gear knob
❑ With boot
❑ Protected
Removing and installing
⇒ page 51authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless
with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Nut
❑ 8 Nm
14 - Gear lever bearing
❑ Removing and installing
⇒ page 52
15 - Bolt
❑ 6 Nm
❑ Secures gear lever bearing to selector housing
16 - Gear lever
❑ Bend points towards rear
17 - Bolt
18 - Nut
❑ 8 Nm
19 - Selector housing
❑ Removing and installing ⇒ page 52

1. Servicing selector mechanism 49

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

20 - Joint
❑ For selector rod/gear lever
21 - Nut
❑ 10 Nm
❑ Self-locking
❑ Renew
22 - Bush

1.4 Servicing selector rod, connecting rod and push rod

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1 - Ball socket
❑ To remove, bend open
peened points on selec‐
tor rod
⇒ Item 19 (page 51) .
2 - 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

3 - Bearing bush with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ To remove pull off re‐

taining clip
⇒ Item 9 (page 50) .
4 - Boot
5 - Gearbox selector lever
6 - Nut
❑ 20 Nm
7 - Bolt
❑ 20 Nm
8 - Connecting rod
❑ To remove pull off re‐
taining clip
⇒ Item 9 (page 50) .
9 - Retaining clip
10 - Bolt
❑ 40 Nm
11 - Push rod
❑ With bush, bolt
⇒ Item 10 (page 50) and
washers
❑ Washer is peened to
push rod
❑ Bush, bolt and washers
cannot be removed from
push rod.
❑ Re-install push rod with the same number of washers
12 - Hexagon socket head bolt
❑ 23 Nm

50 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

13 - Washer
14 - Gear lever bearing
❑ Removing and installing ⇒ page 52
15 - Tensioning ring
❑ For bellows
16 - Bellows
❑ To remove, carefully pull bellows over selector rod ⇒ Item 19 (page 51) and push rod
⇒ Item 11 (page 50) .
❑ When installing, align with markings on selector rod ⇒ Item 19 (page 51) and push rod
⇒ Item 11 (page 50) .
17 - Hexagon socket head bolt
❑ 23 Nm
18 - Clamp
19 - Selector rod
20 - Joint
❑ For selector rod/gear lever
21 - Nut
❑ 10 Nm
22 - Ball stud

1.5 Removing and installing gear knob with

boot
Special tools and workshop equipment required
♦ Hose clip pliers -V.A.G 1275-

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.

Removing

Note

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

– Open ashtray.
– Unclip cover for centre console and lift it off -arrows-.

1. Servicing selector mechanism 51

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Gear knob with clip:

– Pull boot up and over gear knob.
– Open clip -arrow- and pull off gear knob together with boot.

Gear knob with locking mechanism:

– Release connecting piece -1- in direction of -arrow- and pull
gear knob off upwards together with gear lever boot.

Installing
Perform installation in reverse sequence of removal.
– Use a new clip -arrow- to secure gear knob on gear lever.

1.6 Removing and installing selector mech‐

anism
Special tools and workshop equipment required

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.

52 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Engine and gearbox jack -V.A.G 1383 A-

♦ Gearbox support -T10337-

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.

Removing
– Remove gear knob together with boot ⇒ page 51 .
Vehicles with large radio slot:
– Remove operating and display unit for air conditioner ⇒ Air
conditioning system; Rep. gr. 87 .
Vehicles with small radio slot:
– First lift trim panel -1- in direction of -arrow A-, then pull it out
in direction of -arrow B-.
Continued for all vehicles:
– Unscrew bolts -arrows C- and then pull ashtray -2- out of cen‐
tre console.
– Unplug electrical connector for ashtray light.
– Remove foam wedges from centre console.
– Lift out noise insulation.

– Unscrew noise insulation for selector housing -arrows-.

1. Servicing selector mechanism 53

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove nuts -arrows-.

– If fitted, loosen quick-release fasteners -2- and -3- and remove

rear noise insulation -B-.

Vehicles with 2.5 ltr. TDI engine:

– Remove tunnel cross piece (front) -1- -arrows-.
– Disconnect exhaust system at clamp -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
– Remove heat shield for exhaust system -3- from below selec‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

tor mechanism.

– Apply lifting column of engine and gearbox jack -V.A.G 1383

A- to tunnel cross member from below (with gearbox support
-T10337- attached).
– First unscrew bolts -1- and -2- on tunnel cross member, then
bolts -3- and -4-.

54 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Carefully lower tunnel cross member with engine and gearbox

jack -V.A.G 1383 A- until distance between tunnel cross mem‐
ber and body reaches dimension „x“.
♦ Dimension x = 60 mm

Vehicles with 2.7 ltr. TDI engine:

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 flexible pipe connection (de-coupling element) on the front
exhaust pipe must not be bent more than 10° – otherwise it can
be damaged.

– Separate the exhaust system at the clamp -arrow- and slide

the clamp to rear.
– Tie up particulate filter to body (electrical wiring remains con‐
nected).

– Remove heat shield below selector mechanism -arrows-.

– Apply lifting column of engine and gearbox jack -V.A.G 1383

A- to tunnel cross member from below (place a block of wood
-1- between lifting column and tunnel cross member).

Note

The gearbox support -T10337- can also be used in place of the

block of wood -1-.

– Support the tunnel cross member with engine and gearbox

jack -V.A.G 1383 A- .

1. Servicing selector mechanism 55

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

WARNING

The lock carrier must remain installed, and must not be moved
to the service position.

– First remove bolts -1- and then bolts -2-.

– Remove nuts -3- and detach tunnel cross member.
– Lower engine and gearbox jack -V.A.G 1383 A- and move it
aside.

Continued for all vehicles:

– Unscrew connecting rod -2- for selector rod.
– Detach push rod -1-; to do so, unscrew hexagon socket head
bolt.

– Unscrew nut -1- and pull gearbox selector lever -2- off gearbox
selector shaft.
– Swing selector housing with selector rod and push rod down
and remove.
Installing
Installation is carried out in reverse
Protected sequence;
by copyright. Copying fornote
privatethe following:
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
– Fit gearbox selector lever -2- and
with respect to thesecure.
correctnessTightening
of information in torque
this document. Copyright by AUDI AG.
⇒ Item 6 (page 50)

– Secure push rod -1-. Tightening torque ⇒ Item 10 (page 50)

– Secure connecting rod -2-. Tightening torque
⇒ Item 7 (page 50)
– Install tunnel cross member ⇒ page 92 .
– Install exhaust system and perform stress-free alignment ⇒
Rep. gr. 26 .
– Install noise insulation below gearbox.

56 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Secure selector housing -arrows-. Tightening torque

⇒ Item 18 (page 49)
– Adjust selector mechanism ⇒ page 57 .
– Install operating and display unit for air conditioner ⇒ Air con‐
ditioning system; Rep. gr. 87 .
Tightening torques
Component Nm
Heat shield for drive shaft to gearbox 23
Tunnel cross piece (front) to body 55

1.7 Adjusting selector mechanism

The following are prerequisites for correct gear lever alignment:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Gear selector linkage must be in proper conditionpermitted
and undam‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
aged. with respect to the correctness of information in this document. Copyright by AUDI AG.

• Selector mechanism must move freely.

• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
Procedure
– Remove gear knob together with boot ⇒ page 51 .
Vehicles with large radio slot:
– Remove operating and display unit for air conditioner ⇒ Air
conditioning system; Rep. gr. 87 .
Vehicles with small radio slot:
– First lift trim panel -1- in direction of -arrow A-, then pull it out
in direction of -arrow B-.
Continued for all vehicles:
– Unscrew bolts -arrows C- and then pull ashtray -2- out of cen‐
tre console.
– Unplug electrical connector for ashtray light.
– Remove foam wedges from centre console.
– Lift out noise insulation.

– Unscrew noise insulation for selector housing -arrows-.

1. Servicing selector mechanism 57

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Measure distance -a- between the two studs in the selector

mechanism.
♦ Specification: distance a = 85 mm

Note

Measure from centre of one stud to centre of the other.

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

follows:
– Loosen bolt -arrow- for push rod.
• The gear lever bearing should move freely in both directions
on slide
– Set distance -a- by moving gear lever bearing.
– Tighten securing bolt for push rod -arrow-. Tightening torque
⇒ Item 12 (page 50)

– Loosen bolt for selector rod -arrow-.

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

Align the gear lever as follows:

– Position gear lever in centre of ball guide.
• Distance between ball guide and gear lever -arrows- must be
the same at all points.

Align gear lever so that it points slightly (2°) to the right, as seen
in direction of travel. 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
– Hold gear lever in this position. with respect to the correctness of information in this document. Copyright by AUDI AG.

58 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Tighten securing bolt for selector rod -arrow-. Tightening tor‐

que ⇒ Item 17 (page 51)

Note

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

Checking gear lever setting

• 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.
♦ It should only be possible to engage reverse gear after over‐
coming the reverse gear detent.
♦ The gear lever should return by itself from the reverse gear
gate to the 3rd/4th gear gate.
If the gear lever sticks or baulks repeatedly when engaging a
gear, perform the adjustment procedure again.
– Fit covers and gear knob ⇒ page 51 .

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 selector mechanism 59

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

2 Removing and installing gearbox

♦ Removing gearbox - vehicles with 2.5 ltr. TDI engine
⇒ page 60
♦ Installing gearbox - vehicles with 2.5 ltr. TDI engine
⇒ page 69
♦ Removing gearbox - vehicles with 2.7 ltr. TDI engine
⇒ page 75
♦ Installing gearbox - vehicles with 2.7 ltr. TDI engine
⇒ page 84

2.1 Removing gearbox - vehicles with 2.5 ltr. TDI engine

Special tools and workshop

equipment required
♦ Support bracket -10 - 222
A-
♦ Rack -10 - 222 A /1-
♦ Adapters -10 - 222 A /3-
♦ Gearbox support -3282-
♦ Adjustment plate -3282/38-
♦ Engine and gearbox jack -
V.A.G 1383 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.

60 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Wing compensation plate -T40045-

♦ Grease for clutch plate splines -G 000 100-

♦ Copper grease (commercially available)
♦ 2 bolts (M10 x 20)
Procedure

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
♦ All cable ties which are released or cut open during removal
with respect to the correctness of information in this document. Copyright by AUDI AG.

must be fitted in the same position when installing.

♦ Heat insulation sleeves removed during removal of gearbox
must be fitted in the same position when installing.

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– With ignition switched off, disconnect battery earth strap

-arrow-.

– Lift off engine cover -arrows-.

2. Removing and installing gearbox 61

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Detach rubber seal from edges of wing mounting flanges.

– To avoid damaging edges of wing panels with support bracket
-10 - 222 A- , insert wing compensation plates -T40045- on
both sides between the wing mounting flange and the body
panel underneath.

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 support bracket -10-222A- together with racks

-10-222A/1- and adapters -10-222 A/3- .
– Partly take up weight of engine/gearbox assembly with the
spindles.

– On vehicles fitted with auxiliary heater, remove bolts

-arrows- securing exhaust pipe of auxiliary/ additional heater
to noise insulation.

62 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Loosen bolts/quick-release fasteners -1- and -2- and remove

front noise insulation -A-.
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -B-.

– Unbolt bracket for noise insulation -arrows-.

– Remove left and right drive shaft noise insulation from wheel
housing -arrows-.

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– Unbolt drive shaft -1- from flange shaft (left and right) and
move clear to the front, taking care not to damage protective
coating.
– Remove front exhaust pipe with catalytic converter ⇒ Engine,
mechanics; Rep. gr. 26 .

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. Removing and installing gearbox 63

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Audi Cabriolet:
– Unscrew nuts -1- at bottom of engine mountings (left and
right).

– If fitted, unclip operating rod for vehicle level sender -G78-

from lower transverse link -arrow-.

– Before loosening the subframe, use locating pins -3393- to

check whether holes -1- and -2- are aligned.
If this is not the case, wheel alignment has to be checked after
installing the subframe.

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.

– First remove front bolts -2- and -3- on subframe (left and right).
Then remove bolts -1-.
– Lower subframe at the front.

64 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unscrew the three bottom bolts connecting the engine to the

gearbox from the engine side -arrows-.

– Temporarily secure subframe again.

Temporary tightening torque:
1 - approx. 100 Nm
2 - approx. 70 Nm
3 - approx. 70 Nm

WARNING

Do not renew bolts yet or tighten to their final torque. This will
be done when installing the gearbox.

Continued for all vehicles:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew
permittedbottom engine/gearbox
unless authorised securing
by AUDI AG. AUDI bolts
AG does not -arrows-.
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unplug electrical connector -arrow- for engine speed sender -

G28- and move electrical wire clear.

2. Removing and installing gearbox 65

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

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

A- .

Note

The gearbox support -T10337- can also be used in place of the

block of wood -1-.

– First remove bolts -1- and then bolts -2- at tunnel cross mem‐
ber.
– Unscrew the two nuts -3- and detach tunnel cross member.
– Carefully lower engine and gearbox jack -V.A.G 1383 A- and
move it aside.

– Detach connector -arrow- for reversing light switch -F4- at right

side of gearbox.

– Detach push rod -1-; to do so, unscrew hexagon socket head

bolt.
– Unscrew connecting rod -2- for selector rod.

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.

66 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unscrew nut -1- and pull gearbox selector lever -2- off gearbox
selector shaft.

– 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.

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 top engine/gearbox securing bolts -arrows-. While

doing so, note location of bracket -3- (important when instal‐
ling).
– Move bracket -3- with wiring clear to the side and secure with
wire if necessary.
– Unscrew securing bolt -1- (on rear of turbocharger) one turn,
pivot strut -2- in direction of -arrow- and then tighten bolt -1-
again lightly.

– If not already provided, drill a hole of 10.2 mm ∅ -arrow- in the

support elements of gearbox support -3282- .

2. Removing and installing gearbox 67

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Set up gearbox support -3282- for removing manual

gearbox 0A2 with adjustment plate -3282/38- and place on
engine and gearbox jack -V.A.G 1383 A- .

Note

♦ The support elements -arrows- are shown on the adjustment

plate in schematic form; the arrow on the adjustment plate
points in the direction of travel.
♦ Adjustment plate can only be fitted in one correct position.

– Align the adjustment plate parallel to the gearbox.

– Secure support elements to left side of gearbox, as shown in
illustration. Tighten bolt (M10 x 20) -arrow on right side- to
20 Nm.

– Secure support elements to right side of gearbox, as shown in

illustration. Tighten bolt (M10 x 20) -arrow on left side- to
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
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unbolt starter -1- from engine/gearbox -arrows- and secure as

necessary ⇒ Electrical system; Rep. gr. 27 .

Note

Starter cables do not have to be disconnected.

68 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove remaining engine/gearbox connecting bolt

-arrow A-.
– Press gearbox off dowel sleeves.
– Carefully lower gearbox, making sure there is sufficient clear‐
ance from drive shafts.
– Before carrying out assembly work, secure gearbox to assem‐
bly stand , using engine and gearbox support -VW 540-
⇒ page 90 .

– If the removed gearbox is being renewed, the gearbox mount‐

ing -1- must be transferred to the replacement gearbox. Tight‐
ening torque for bolts -2- ⇒ page 92 .

2.2 Installing gearbox - vehicles with 2.5 ltr.

TDI engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried outunless
permitted in reverse
authorised sequence; note
by AUDI AG. AUDI the not
AG does following:
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Use a thread tap to remove any remaining locking fluid from
all threaded holes which will accommodate self-locking bolts.
– Always renew self-locking bolts and nuts.
– 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 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 9 (page 30) .
– If plastic ring -arrows- has come loose, service release bearing
as required ⇒ page 31 .

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.
– If fitted, 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.

2. Removing and installing gearbox 69

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Place gearbox on engine and gearbox jack .

– Align adjustment plate and gearbox parallel to one another.
– Attach support elements -arrows- on right side of gearbox.

– Attach support elements -arrow A- and -arrow B- on left side

of 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.

– Before installing gearbox, check that brace -B- is still moved

to one side -direction of arrow-.

– 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-.

70 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Secure clutch slave cylinder with new bolt -arrow-. Tightening

torque ⇒ Item 2 (page 30)

Caution

♦ 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
Protected cylinder
by copyright. isforlikely
Copying private to have been
or commercial purposes, in part or in whole, is not
guided past the clutch
permitted release
unless lever.
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 slave cylinder would then be destroyed once pedal
force exceeds approx. 300 N.
♦ For comparison: normal pedal force is approx. 115 N.

– Insert gearbox, making sure there is sufficient clearance to

drive shafts.
– When aligning the gearbox with the engine, turn crankshaft
back and forth slightly to make inserting the gearbox input
shaft splines into the clutch plate easier.

– Insert connecting bolts at top and side of engine/gearbox as‐

sembly -arrows- and tighten. Secure bracket -3- at the same
time.
– Tighten bolt -1- on top brace for turbocharger to 22 Nm.

– Install gearbox selector lever and tighten nut -arrow-. Tight‐

ening torque ⇒ Item 6 (page 50)

2. Removing and installing gearbox 71

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Install push rod -1-; to do so, tighten hexagon socket head bolt.
Tightening torque ⇒ Item 10 (page 50)
– Secure connecting rod -2- for selector rod. Tightening torque
⇒ Item 7 (page 50)

– Raise gearbox using engine and gearbox jack -V.A.G 1383 A-

and secure tunnel cross member to body (finger-tight), using
new bolts -2- and -3-.
– Bolt tunnel cross member onto gearbox mounting -4-. Tight‐
ening torque ⇒ Item 7 (page 92)
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .

Audi Cabriolet:
– First remove front bolts -2- and -3- on subframe (left and right).
Then remove bolts -1-.
– Lower subframe at the front.

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.

– Tighten the three lower engine/gearbox securing bolts at bot‐

tom -arrows- to torque setting.

72 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Renew front subframe bolts -1 ... 3- on both sides of the vehi‐

cle. Tighten bolts hand-tight only.

Before tightening the subframe mountings, the subframe must be

aligned with the body using locating pins -3393- .
• Hole -1-, hole -2- in subframe and hole -3- in aluminium brack‐
et must be in alignment on both sides.

Note

This alignment can only replace a subsequent wheel alignment

check if holes -1- and -2- coincided before the repair work was
carried out.

– Secure subframe mountings ⇒ Running gear, front-wheel

drive and four-wheel drive; Rep. gr. 40 .

– Tighten nuts -1- for engine mountings ⇒ Engine, mechanics;

Rep. gr. 10 .

Note

-Item 2- can be disregarded.

Continued for all vehicles:

– Tighten bolts -1 … 3- for tunnel cross member. Tightening tor‐
ques ⇒ page 92

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. Removing and installing gearbox 73

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Tighten the three lower engine/gearbox securing bolts at bot‐

tom -arrows- to torque setting.
The remaining installation steps are carried out in the reverse se‐
quence; note the following points:
– Install starter ⇒ Electrical system; Rep. gr. 27 .
– Install exhaust system so it is free of stress ⇒ Engine, me‐
chanics; Rep. gr. 26 .
– Check selector mechanism setting and adjust if necessary
⇒ page 57 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. gr. 27 .

Caution

Never use a charger to aid starting. Otherwise, the vehicle's

control units could be damaged.

– If necessary, check wheel alignment ⇒ Running gear, front-

wheel drive and four-wheel drive; Rep. gr. 44 .
♦ A wheel alignment check is not necessary if the alignment of
the subframe in relation to the body was checked using locat‐
ing pins -3393- prior to dismantling and assembly of the sub‐
frame (before tightening bolts).
♦ A wheel alignment check must, however, be carried out if the
alignment of the subframe relative to the body was not
checked or if it was not possible to fully insert the two locating
pins -3393- into the holes.
– Check gear oil level in gearbox ⇒ page 95 .
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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Do not use parts which have been degreased. 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.
♦ Tolerance for tightening torques is ± 15%.

74 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Gearbox to engine
Item Bolt Nm
1 M12 x 67 65
2 (1 M12 x 75 65
3 2) M12 x 90 65
4 M12 x 75 65
5 3) M10 x 50 45
6, 7, 8 M10 x 45 45
9, 10 4) M12 x 110 65
11 M12 x 67 65
A Dowel sleeves for centralising
1) With strut for turbocharger
2) With bracket for wiring
3) Hammer head bolt with nut
4) Starter to gearbox

Component Nm
Heat shield for drive shaft to gearbox 23
Engine mounting to engine support 23
Bracket for noise insulation to subframe 10

2.3 Removing gearbox - vehicles with 2.7 ltr. TDI 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.

2. Removing and installing gearbox 75

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Special tools and workshop

equipment required
♦ Support bracket -10 - 222
A- (Audi A4 Cabriolet only)
♦ Rack -10 - 222 A /1- (Audi
A4 Cabriolet only)
♦ Adapter -10 - 222 A /3- (Au‐
di A4 Cabriolet only)
♦ Gearbox support -3282-
♦ Adjustment plate -3282/38-
♦ Engine and gearbox jack -
V.A.G 1383 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.

♦ Wing compensation plates -T40045- (Audi A4 Cabriolet only)

♦ Grease for clutch plate splines -G 000 100-

♦ Copper grease (commercially available)
♦ 2 bolts (M10 x 20)

76 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Note

♦ All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
♦ Heat insulation sleeves removed during removal of gearbox
must be fitted in the same position when installing.

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– With ignition switched off, disconnect battery earth strap

-arrow-.

– On vehicles fitted with auxiliary heater, remove bolts

-arrows- securing exhaust pipe of auxiliary/ additional heater
to noise insulation.

– Loosen bolts/quick-release fasteners -1- and -2- and remove

front noise insulation -A-.
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -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.

2. Removing and installing gearbox 77

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unbolt bracket for noise insulation -arrows-.

– Remove left and right drive shaft noise insulation from wheel
housing -arrows-.

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– Unbolt drive shafts -1- (left and right) from gearbox flange
shafts.

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

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

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 front exhaust pipe with particulate filter ⇒ Engine,

mechanics; Rep. gr. 26 .

– Unbolt bracket for exhaust pipe (left-side) on gearbox

-arrows-.

78 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Audi A4 Cabriolet:
– Remove bottom nuts -1- on engine mountings (left and right).

Note

-Item 2- can be disregarded.

– Carefully detach engine cover panel from the four retaining

studs -arrows- one by one.

– Detach rubber seal from edges of wing mounting flanges.

– To avoid damaging edges of wing panels with support bracket
-10 - 222 A- , insert wing compensation plates -T40045- on
both sides between the wing mounting flange and the body
panel underneath.

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. Removing and installing gearbox 79

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Set up support bracket -10 - 222 A- with racks -10 - 222 A /1-
and adapters -10-222 A /3- .
– Raise engine/gearbox assembly slightly at the front via the
spindle.

Continued for all vehicles:

– Unbolt anti-roll bar mountings on left and right sides (-1- and
-2-) and pivot anti-roll bar downwards.

– Remove engine/gearbox bolts -6 ... 10- (accessible from be‐

low).
Audi A4 Cabriolet:
– Lower engine/gearbox assembly again.

Continued for all vehicles:

– Unplug electrical connector -arrow- for engine speed sender -
G28- and move electrical wire clear.

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 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove nut -bottom arrow- and bolt -top arrow-, but do not
remove starter.

– Slacken nuts -arrows- at stop for torque reaction support.

– Press stop for torque reaction support upwards using a lever
and tighten nuts again.

Note

Adjusting the stop for torque reaction support prevents the engine
from tilting at the front after the gearbox is removed.

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

A- .

Note

The gearbox support -T10337- can also be used in place of the

block of wood -1-.

WARNING

Risk of injury
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The lock carrier must remain installed, and mustunless
permitted not authorised
be by AUDI AG. AUDI AG does not guarantee or accept any liability
moved to the service position. with respect to the correctness of information in this document. Copyright by AUDI AG.

– First remove bolts -1- and then bolts -2- at tunnel cross mem‐
ber.
– Unscrew the two nuts -3- and detach tunnel cross member.
– Carefully lower engine and gearbox jack -V.A.G 1383 A- and
move it aside.

2. Removing and installing gearbox 81

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Detach connector -arrow- for reversing light switch -F4- at right

side of gearbox.

– Unplug electrical connector -1- on exhaust gas pressure sen‐

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

sor 1 -G450- and move electrical wiring

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

– Remove bolts -arrows- and detach pressure lines.

– Detach push rod -1-; to do so, unscrew hexagon socket head

bolt.
– Unscrew connecting rod -2- for selector rod.

– Unscrew nut -1- and pull gearbox selector lever -2- off gearbox
selector shaft.

82 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

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

with wire; do not open pipe/hose system.

Note

Do not depress clutch pedal after removing slave cylinder.

– If not already provided, drill a hole of 10.2 mm ∅ -arrow- in the

support elements of gearbox support -3282- .

– Set up gearbox support -3282- for removing manual

gearbox 0A2 with adjustment plate -3282/38- and place on
engine and gearbox jack -V.A.G 1383 A- .

Note

♦ The support elements -arrows- are shown on the adjustment

plate in schematic form; the arrow on the adjustment plate
points in the direction of travel.
♦ Adjustment plate can only be fitted in one correct position.
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.

– Align the adjustment plate parallel to the gearbox.

– Secure support elements to left side of gearbox, as shown in
illustration. Tighten bolt (M10 x 20) -arrow on right side- to
20 Nm.

2. Removing and installing gearbox 83

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Secure support elements to right side of gearbox, as shown in

illustration. Tighten bolt (M10 x 20) -arrow on left side- to
20 Nm.

– Remove remaining engine/gearbox bolts -3 ... 5-.

– Press gearbox off dowel sleeves.
– Carefully lower gearbox, making sure there is sufficient clear‐
ance from drive shafts.
– Before carrying out assembly work, secure gearbox to assem‐
bly stand , using engine and gearbox support -VW 540-
⇒ page 90 .

– If the removed gearbox is being renewed, the gearbox mount‐

ing -1- must be transferred to the replacement gearbox. Tight‐
ening torque for bolts -2- ⇒ Item 3 (page 92) .

2.4 Installing gearbox incopyright.

Protected by vehicles Copying with 2.7
for private ltr. 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
TDI engine with respect to the correctness of information in this document. Copyright by AUDI AG.
Installation is carried out in reverse sequence; note the following:
– Use a thread tap to remove any remaining locking fluid from
all threaded holes which will accommodate self-locking bolts.
– Always renew self-locking bolts and nuts.
– 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 guide sleeve.
• It should be possible to push the clutch plate back and forth
slightly on the input shaft.

84 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Check clutch release bearing for wear and renew if necessary

⇒ Item 9 (page 30) .
– If plastic ring -arrows- has come loose, service release bearing
as required ⇒ page 31 .

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.
– If fitted, 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.

– Place gearbox on engine and gearbox jack .

– Align adjustment plate and gearbox parallel to one another.
– Attach support elements -arrows- on right side of gearbox.

– Secure support elements -arrow A- and -arrow B- to left side

of 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.

2. Removing and installing gearbox 85

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– 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 clutch slave cylinder with new bolt -arrow-. Tightening

torque ⇒ Item 2 (page 30)

Caution

♦ Press the clutch pedal carefully after installing the gear‐

box.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦permitted
If youunless
feelauthorised
an unusually
by AUDI AG.strong
AUDI AG point ofguarantee
does not resistance when
or accept any liability
depressing
with respect to thethe clutch
correctness pedal, you
of information in thismust notCopyright
document. pressbyit AUDI
down AG.
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.

– When aligning the gearbox with the engine, turn crankshaft

back and forth slightly to make inserting the gearbox input
shaft splines into the clutch plate easier.
– Bolt gearbox onto engine.

– Install gearbox selector lever and tighten nut -arrow-. Tight‐

ening torque ⇒ Item 6 (page 50)

86 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Install push rod -1-; to do so, tighten hexagon socket head bolt.
Tightening torque ⇒ Item 10 (page 50)
– Secure connecting rod -2- for selector rod. Tightening torque
⇒ Item 7 (page 50)

– Tighten bolts -1 … 3- for tunnel cross member ⇒ page 92 .

– Loosen bolts -arrows- for torque reaction support.

– Allow stop for torque reaction support to settle on rubber buffer
for torque reaction support under its own weight and re-tighten
bolts.
The remaining installation steps are carried out in the reverse se‐
quence; note the following points:
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Install front exhaust pipe with particulate filter ⇒ Engine, me‐
chanics; Rep. gr. 26 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. gr. 27 .

Caution

Never use a charger to aid starting. Otherwise, the vehicle's

control units could be damaged.

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

♦ 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%.

2. Removing and installing gearbox 87

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Gearbox to engine
Item Bolt Nm
1, 2 M10 x 125 65 1)
3, 4, 5 M12 x 105 65
6, 7 M12 x 120 65
8, 9, 10 M10 x 80 45
A Dowel sleeves for centralising
1) Property class 10.9.

Component Nm
Heat shield for drive shaft to gearbox 23
Engine mounting to engine support 23
Bracket for noise insulation to subframe 10
Stop for torque reaction support 28

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.

88 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

3 Transporting gearbox
Special tools and workshop equipment required
♦ Lifting aid -T40013-

♦ Workshop hoist -VAS 6100-

Procedure
– Insert lifting aid -T40013- in lifting eye on gearbox and secure.
– Engage hook of workshop hoist in 4th notch -arrow- on lifting
aid .
– Lift gearbox with workshop hoist and lifting aid -T40013- .

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. Transporting gearbox 89
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

4 Mounting gearbox on assembly stand

Special tools and workshop

equipment required
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Workshop hoist -
VAS 6100-
♦ Lifting aid -T40013-

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.

Procedure
– Insert lifting aid -T40013- in lifting eye on gearbox and secure.
– Fasten hook of workshop crane -VAS 6100- in 4th notch
-arrow- on lifting tackle -T40013- .
– Lift gearbox with workshop hoist -VAS 6100- and lifting aid -
T40013- .

90 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Secure engine and gearbox support -VW 540- to gearbox and

fit into support clamp -VW 313- or engine and gearbox support
-VAS 6095- .

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. Mounting gearbox on assembly stand 91

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

5 Exploded view - gearbox mounting and tunnel cross member

1 - Gearbox
❑ Removing and installing
⇒ page 60
2 - Gearbox mounting
❑ Removing and installing
⇒ page 92
3 - Bolts
❑ 23 NmProtected 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
4 - Tunnel cross member
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing and installing

⇒ page 92
5 - Bolts
❑ 65 Nm
6 - Bolts
❑ 110 Nm + 90°
❑ Always renew
7 - Nut
❑ 23 Nm

5.1 Removing and installing gearbox

mounting and tunnel cross member
Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383 A-

92 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

Removing
– If fitted, open quick-release fasteners -2 ... 3- and detach rear
noise insulation -B-.

– Disconnect exhaust system at clamp -arrows-.

– Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox

up slightly. Insert a wooden block -1- between gearbox and
gearbox jack.

Note

The gearbox support -T10337- can also be used in place of the

block of wood -1-.

– First remove bolts -3- and then bolts -2- at tunnel cross mem‐
ber.
– Lower gearbox slightly. 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

– Unscrew the two nuts -1- and push tunnel cross member
with respect to the correctness of information in this document. Copyright by AUDI AG.

backwards slightly.

5. Exploded view - gearbox mounting and tunnel cross member 93

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove bolts -2- for gearbox mounting -1- and detach gear‐
box mounting.
Installing
Installation is carried out in reverse sequence; note the following:
– Secure gearbox mounting -1- with bolts -2-. Tightening torque
⇒ Item 3 (page 92)

– Bolt tunnel
permittedcross member by onto gearbox mounting -1-.orTight‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised AUDI AG. AUDI AG does not guarantee accept any liability
ening torque ⇒ Item
with respect 7 (pageof92)
to the correctness information in this document. Copyright by AUDI AG.

– Lift gearbox until bolts -2- can be fitted.

– Screw in bolts -2- and bolts -3- hand-tight.
– Tighten bolts -2-. Tightening torque ⇒ Item 6 (page 92)
– Tighten bolts -3-. Tightening torque ⇒ Item 5 (page 92)
– Install exhaust system so it is free of stress ⇒ Engine, me‐
chanics; Rep. gr. 26 .
– Install noise insulation below gearbox.

94 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

6 Checking oil level in manual gearbox

Procedure

Note

The vehicle must be horizontal when checking gear oil level.

The prescribed oil level is to be adhered to exactly; the gearbox

reacts very sensitively to over-filling.
Gear oil level is checked with gearbox installed.
– To check gear oil level, unscrew oil filler plug -arrow-.
– Check oil level with a suitable tool (such as a length of wire
bent to shape).
• The oil level is correct when gearbox oil is up to 2 mm ± 1 mm
below bottom lip of filler hole.
– Top up with gear oil if necessary. Specifications ⇒ Electronic
parts catalogue .
– Screw in oil filler plug -arrow-.
Tightening torque
Component Nm
Oil filler plug 40
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.

6. Checking oil level in manual gearbox 95

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

7 Removing and installing reversing

light switch -F4-
Removing
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -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.

– Unplug connector -arrow- for reversing light switch -F4- on

right side of gearbox.
– Unscrew reversing light switch -F4- from selector shaft cover
-arrow-.
Installing
Perform installation in reverse sequence of removal.
Tightening torque
Component Nm
Reversing light switch -F4- in selector shaft cover 20

96 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

8 Renewing oil seal for selector shaft

with gearbox installed
Special tools and workshop equipment required
♦ Tube -VW 423-

♦ Extractor tool -T20143/1-

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.

♦ Assembly sleeve -01E 311 120-

♦ Sealing grease -G 052 128 A1-
Removing
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -B-.

– Detach drive shaft noise insulation (left-side) from wheel hous‐

ing -arrows-.

8. Renewing oil seal for selector shaft with gearbox installed 97

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– Remove front exhaust pipe with catalytic converter ⇒ Engine,
mechanics; Rep. gr. 26 .

– Unscrew nut -1- and pull gearbox selector lever -2- off gearbox
selector shaft.

– Carefully lever out oil seal with extractor tool -T20143/1- , tak‐
ing care not to damage selector shaft. 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
• Check selector shaft for damage. with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
– To avoid damaging oil seal -C-, always use assembly sleeve
-01E 311 120- -A- when installing oil seal and selector shaft.

98 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease -G 052 128 A1- .
– Lightly oil outer circumference of oil seal.

– Drive oil seal -arrow- into housing as far as it will go.

– Secure gearbox selector lever with nut -1-. Tightening torque

⇒ Item 6 (page 50)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The remaining
permitted unlessinstallation steps
authorised by AUDI AG. are
AUDIcarried
AG does notout in theorreverse
guarantee accept any se‐
liability
quence;
withnote
respectthe following
to the correctness points:
of information in this document. Copyright by AUDI AG.

– Install exhaust system so it is free of stress ⇒ Engine, me‐

chanics; Rep. gr. 26 .
– Check gear oil level in gearbox ⇒ page 95 .
Tightening torques
Component Nm
Heat shield for drive shaft to gearbox 23

8. Renewing oil seal for selector shaft with gearbox installed 99

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

9 Removing and installing selector

shaft
The selector shaft can only be removed and installed with the
gearbox removed ⇒ Servicing 6-speed manual gearbox 0A3,
four-wheel drive; Rep. gr. 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

100 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

10 Removing and installing selector

shaft locking bushes (with gearbox
installed in vehicle)
Special tools and workshop equipment required
♦ Multi-purpose tool -VW 771-

♦ Puller -T40054/1 - and T40054/2

Removing
– On vehicles fitted with auxiliary heater, remove bolts
-arrows- securing exhaust pipe of auxiliary/ additional heater
to noise insulation.

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.
– Open quick-release fasteners -1 ... 3- and detach front and
rear noise insulation.

10. Removing and installing selector shaft locking bushes (with gearbox installed in vehicle) 101
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Unplug electrical connector -1- at reversing light switch -F4- .

– If clutch pipe bracket -2- is fitted, remove bolt -arrow- and de‐
tach bracket.

– Screw spindle of multi-purpose tool -VW 771- into stem of

puller -T40054/1 - .
– Fit puller onto locking bush -arrow A-.
– Secure puller by sliding on sleeve -T40054/2- as far as stop in
direction of -arrow-.
– Drive out locking bush upwards using multi-purpose tool -VW
771- .

Note

The other locking bush -arrow B- is removed in the same manner.

Installing
– Lightly oil stems of locking bushes and holes in gearbox with
gear oil.
– Place locking bush in puller -T40054/1- -arrow A- and secure
it in place by sliding down sleeve -T40054/2- .
– Use multi-purpose tool -VW 771- to drive locking bush into
gearbox as far as stop.

Note

♦ Make sure locking bushes remain in straight position when in‐

stalling.
♦ The other locking bush -arrow B- is installed in the same man‐
ner.

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.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Plug connector -1- onto reversing light switch -F4- .

– If fitted, secure clutch pipe bracket -2- together with connecting
rod -arrow-. Tightening torque ⇒ Item 7 (page 50)
– Install noise insulation panels.

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. Removing and installing selector shaft locking bushes (with gearbox installed in vehicle) 103
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

11 Dismantling and assembling gearbox

Dismantling and assembling gearbox ⇒ Servicing 6-speed man‐
ual gearbox 0A2, front-wheel drive; Rep. gr. 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

104 Rep. gr.34 - Controls, housing

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

35 – Gears, shafts
1 Input shaft
Dismantling and assembling input shaft ⇒ Servicing 6-speed
manual gearbox 0A2, front-wheel drive; Rep. gr. 35

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. Input shaft 105

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

2 Pinion shaft
Dismantling and assembling pinion shaft ⇒ Servicing 6-speed
manual gearbox 0A2, front-wheel drive; Rep. gr. 35

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.

106 Rep. gr.35 - Gears, shafts

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

39 – Final drive - differential

1 Renewing flange shaft oil seals (left
and right)

1.1 Renewing flange shaft oil seal (left-side)

with gearbox installed in vehicle
Special tools and workshop equipment required
♦ Drift -VW 295-

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

♦ Thrust piece -T10387-

1. Renewing flange shaft oil seals (left and right) 107

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

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

♦ Sealing grease -G 052 128 A1-

Removing
Observe the general repair instructions ⇒ page 6 .
– Remove front left wheel.
– Loosen bolts/quick-release fasteners -1- and -2- and remove
front noise insulation -A-.
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -B-.

– Remove left drive shaft noise insulation from wheel housing

-arrows-.

– Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts).

– Detach drive shaft -1- from flange shaft and tie as far as pos‐
sible to front, taking care not to damage surface protection.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
derneath.

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.

108 Rep. gr.39 - Final drive - differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove flange shaft (left-side); to do so, secure puller -

T10037- to cover for final drive -arrow-.

– Lever out flange shaft oil seal using a suitable lever.

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

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 flange shaft oil seals (left and right) 109

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Lightly oil outer circumference of new oil seal.

– Drive in new flange shaft oil seal using thrust piece -T10387-
until thrust piece reaches stop; keep seal straight when instal‐
ling.

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.

– Knock flange shaft in with drift -VW 295- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The remaining installation
permitted steps
unless authorised are
by AUDI AG.carried
AUDI AG outdoes in
notthe reverse
guarantee se‐any liability
or accept
quence; note the following points:
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel

drive and four-wheel drive; Rep. gr. 40 .
– Bolt on heat shield for drive shaft (left-side).
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 95 .
– Install noise insulation panels.
Tightening torque
Component Nm
Heat shield for drive shaft to gearbox 23

1.2 Renewing flange shaft oil seal (right-

side) with gearbox installed in vehicle
Special tools and workshop equipment required
♦ Drift -VW 295-

110 Rep. gr.39 - Final drive - differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

♦ Puller -T10037-

♦ Thrust piece -T10387-

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.

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

♦ Sealing grease -G 052 128 A1-

Removing
Observe the general repair instructions ⇒ page 6 .
– Remove front right wheel.
– Loosen bolts/quick-release fasteners -1- and -2- and remove
front noise insulation -A-.
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -B-.

1. Renewing flange shaft oil seals (left and right) 111

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

– Remove right drive shaft noise insulation from wheel housing

-arrows-.

– If fitted, remove heat shield forProtected

drive shaft (right-side)
by copyright. Copying for private or commercial purposes, in part or in whole, is not
-arrow-. 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 drive shaft (right-side) from flange shaft and tie as far
as possible to front, taking care not to damage surface pro‐
tection.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
derneath.

– Remove flange shaft (right-side); to do so, secure puller -

T10037- to gearbox housing -arrow-.

– Lever out flange shaft oil seal -arrow- using a suitable lever.

112 Rep. gr.39 - Final drive - differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

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

– Lightly oil outer circumference of new oil seal.

– Drive in new flange shaft oil seal using thrust piece -T10387-
until thrust piece reaches stop; keep seal straight when instal‐
ling.

Note

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

ing
♦ 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 oil level in gearbox and top up with gear oil if necessary
⇒ page 95 .
– Install noise insulation.
Tightening torque
Component Nm
Heat shield for drive shaft 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 flange shaft oil seals (left and right) 113

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

2 Differential

2.1 Removing and installing differential

Removing and installing differential ⇒ Servicing 6-speed manual
gearbox 0A2, front-wheel drive; Rep. gr. 39

2.2 Dismantling and assembling differential

Dismantling and assembling differential ⇒ Servicing 6-speed
manual gearbox 0A2, front-wheel drive; Rep. gr. 39

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.

114 Rep. gr.39 - Final drive - differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 0A2, front-wheel drive - Edition 12.2010

3 Adjusting pinion shaft and crown

wheel
Adjusting pinion shaft and crown wheel ⇒ Servicing 6-speed
manual gearbox 0A2, front-wheel drive; Rep. gr. 39

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. Adjusting pinion shaft and crown wheel 115