Service of Audi A4 from 2001 to 2005 release.
1. Operation and maintenance of the car
2. Engine
3. Transmission
3.1. Coupling
3.2. Mechanical transmission
3.2.1. Six-speed transmission 0A3 (four-wheel drive)
3.2.2. Six-speed transmission 01E/0A1 (forward drive)
3.2.3. General recommendations about prevention and repair of mechanical transmissions
3.2.4. Check of level of gearbox oil in the mechanical transmission
3.2.5. Removal and installation of a knob with a cover
3.2.6. Removal and installation of the drive of gear shifting
3.2.7. Adjustment of the drive of gear shifting
3.2.8. Removal and installation of a pillow of the transmission
3.2.9. Removal and installation of lock plugs of a shaft of gear shifting at the installed transmission
3.2.10. Removal of switches of lamps of a backing
3.3. Automatic transmission
3.4. Driving mechanism
3.5. Tables
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Schemes of electric equipment
 




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3.2.3. General recommendations about prevention and repair of mechanical transmissions

Transmission
Bolts and other details should be selected according to an alphabetic code of the transmission.
When replacing the transmission check oil level in a box and if necessary add.
Carefully clear junctions and a surface of a reducer.
At installation of the transmission you watch the correct position of the aligning plugs.
Shnurovy consolidations, laying, sealing cuffs.
Ring shnurovy consolidations, laying and sealing cuffs are subject to replacement by new.
After removal of consolidations examine airfields on the case and on a shaft on existence of damages at dismantle.
Carefully clear the dividing surfaces of the case before assembly.
Sealing rings for radial consolidation of a shaft before installation should be greased slightly on external diameter and to fill in them space between edges to a half the pressurizing plastic lubricant.
Establish the open party of a sealing cuff to the condensed liquid.
The new sealing cuff is squeezed and exactly established to the place of old. (Use the device for a deep press fitting).
Before installation slightly grease sealing rings to prevent crush of rings at installation.
After replacement of consolidations and sealing rings check oil level in the transmission.

Sealant
Carefully clear the dividing surfaces of the case before putting sealant.
Apply sealant with uniform and not too thick layer.
Sealant should not get to air vents.

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

Fig. 3.45. Scheme of installation of lock rings


Replace tightening plugs. Arrangement: vents And it is located along distribution of loading (fig. 3.45).

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

Bolts, nuts
Unscrew bolts / nut as it should be, the return to twisting.
Consistently establish all bolts and nuts for fastening of covers and the case without screwing up and then crosswisely tighten.
Do not warp especially easily damaged details, for example coupling plates, turn off and tighten them cross-wise, gradually.
The moments of an inhaling are given for ungreased bolts and nuts.
Самоконтрящиеся bolts and nuts are subject to replacement.
Clear a carving of the bolts / screws greased at an inhaling with a carving clamp a wire brush. Then insert screws with a clamp.
Carving openings in which the self-stopped screws or screws with a clamp were twisted need to be cleared (for example, by means of a tap). Otherwise at the following dismantling their thread can be stripped.

Bearings
Get needle bearings the marked party (thicker part) to the tool for a press fitting.
Note the needle bearing of the switched gear wheel of 1-6 transfers at removal that at assembly to establish them in the same situation.
Grease the needle bearing of a power shaft of the transmission behind in a flywheel.
Install all bearings in the transmission case with gearbox oil.
Heat internal rings of conic roller bearings before installation approximately to 100 °C, at installation press without axial side plays against the stop.
Do not mix external and internal rings of bearings, identical by the size.
Always replace the conic roller bearings located on one shaft assembled and use products of one producer.
Conic roller bearings of a power shaft and differential in the transmission work with small losses on friction. In addition do not grease new conic roller bearings for measurement of the moment of friction forces. For this purpose at the plant bearings process special oil.

Adjusting washers
Control the size of adjusting washers in several points by means of a micrometer. Various admissions give the chance to precisely measure the required thickness of washers.
Check for existence of agnails or damages.
Use only the faultless and intact adjusting washers.

Gear wheels, synchronizers, internal rings switched by a gear wheel
Heat gear wheels and synchronizers before installation approximately to 100 °C, at installation press without axial side plays against the stop.
For installation of the internal rings switched by a gear wheel heat them approximately to 100 °C.
Temperature can be checked by means of the thermometer.
You monitor the assembly provision.

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

The blocking synchronizer rings
At reuse of a ring of the synchronizer identify on a gear wheel of the same transfer and do not mix.
Check the blocking rings for wear existence; if necessary replace.
Establish, having oiled gearbox.

Synchronizer locks with a molybdenic covering
The surface of friction of the efficient lock of the synchronizer with a molybdenic covering looks as graphite and has slightly porous surface (the lock needs to be cleaned). The surface of friction has to be fat-free

Fig. 3.46. "Attritions" on the surface of friction of the lock of the synchronizer


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

Wear of the switched inclusion gear wheels / plugs

Fig. 3.47. Wear of the lock of the synchronizer or the switched gear wheel: A – worn-out bevel of teeths of the lock of the synchronizer or gear wheel


Wear of the lock of the synchronizer or the switched gear wheel it is shown in the figure 3.47.

Fig. 3.48. Intact lock of the synchronizer: B – Normal bevel of teeths of the lock of the synchronizer or gear wheel


The intact lock a synchronizer / gear wheel is shown in the figure 3.48.

Fig. 3.49. Wear of the plug of inclusion: C – worn-out bevel of teeths of the plug of inclusion


Wear of the plug of inclusion is shown in the figure 3.49.

Fig. 3.50. Intact plug of inclusion: D – Normal bevel of teeths of the plug of inclusion


The intact plug of inclusion is shown in the figure 3.50.
Sikhronizator locks with a carbonic covering change together with the inclusion plug. Depending on a picture of wear replace also switched gear wheels.

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


3.2.2. Six-speed transmission 01E/0A1 (forward drive)

3.2.4. Check of level of gearbox oil in the mechanical transmission