Contents

00 Technical data Page

Gearbox identification 00- 1

- Code letters, allocation, ratios, capacities 00- 3
Final drive identification 00- 5
- Code letters, allocation, ratios, capacities 00- 7
Power flow diagram 00- 8
Calculation of transmission rati 00- 9
Notes regarding output test, brake test and towing vehicle 00-10
General repair instructions 00-11

30 Clutch Page

Servicing clutch mechanism 30- 1

- List of operations for pedal cluster (3.6 litre engine) 30- 1
- Removing and installing over-centre spring 30- 8
- List of operations for pedal cluster (4.2 litre engine) 30- 9
- Removing and installing over-centre spring 30-16
- List of operations for hydraulics *)
- Bleeding clutch system *)
Servicing clutch release mechanism *)
Servicing clutch 30-17

34 Controls, Housing Page

Servicing selector mechanism *)

Adjusting and checking selector mechanism *)
Removing and installing gearbox 34- 1
- Removal 34- 1
- Installation 34- 13
Removing and installing oil pump 34-17
- Removal 34-17
- Installation 34-20

39 Final drive, Differential Page

Replacing flanged shaft seal 39- 1

Replacing electronic speedometer sender and gear 39- 2
Replacing flange/propshaft seal at gearbox 39- 4
- Sequence of operations 39- 6
Removing and installing propshaft 39-10
- Sequence of operations 39- 13
- Adjusting 39-18
Replacing flange/propshaft seal_at rear final drive 39-22
- Sequence of operations 39-24
Replacing oil seal for right flanged shaft 39-37
Replacing oil seal for left flanged shaft 39-41
Removing and installing rear final drive 39-47
- Removal 39-47
- Installation 39- 58

*) Not described in this booklet

=> Workshop Manual Audi 100 1991
Booklet 5- and 6-Speed Manual Gearbox 01 E Edition 01 .92
 Gearb9x identification ·
The 6-speed manual gearbox 01E4 WO is installed
in the Audi VB from 07.91 in combination with the
3.6 litre and 4.2 litre 8-cylinderfuel injection engines.

..... Location on gearbox

Code letters and serial No. (arrow 1)

Manual gearbox 01 E (arrow 2)

00-1

..... Code letters and serial number of ge_arbox (arrow 1).

Example: CBN 00041

I
Code
I
Serial number
letters of gearbox

Note:

~ The code letters of the gearbox are also listed in the

. vehicle ·data plates.

..... Manual gearbox 01 E (arrow 2):

00-2
 Code letters, allocation, ratios, capacities

Manual gearbox 6-speed 01 E 4 WO

Code letters CBM CBN

Manufactured from 07.91 07.91

to

Allocation Type/Model Audi V8 1991 ...

Engine: 8-cylinder 3.61-184 kW 3.6 I - 184 kW *)

V engine 4.21-206 kW

Ratios Final drive 37: 9 = 4.111 37: 9=4.111

Z2: Z1 = i Gearbox 1st gear 28: 8 = 3.500 28: 8 = 3.500

2nd gear 34:18 = 1.~89 34:18 = 1.889

3rd gear 33:25 = 1.320 32:26 = 1.231

4th gear 30:29 =1.034 29:30 = 0.967

5th gear 30:35 = 0,857 29:36 = 0.806

6th gear 27:37 = 0.730 26:38 = 0.684

Reverse 38:11 = 3.455 38:11 = 3.455

Speedometer electronic 8 pulses I wheel revolution

Remarks *) Switzerland

00-3

Code letters, allocation, ratios, capacities

Manual gearbox

Code letters CBM CBN

• Capacity 3.5 I *) + 0.1 I gear oil additive Part No. G 009 000 01

Specification Gear'oil G 50 (synthetic oil) SAE 75 W-90

Clutch mechanism hydraulic

Clutch plate dia. 240mm

Drive shaft flange dia. 108mm

Total ratio in top gear 3.000 2.813

Allocation Rear final drive AXZ

(code letters)

Remarks *) + 0.3 I for oil pipes and oil cooler

00-4
 Final drive identification Tightening torques:

- The final drive 017 is also allocated to the manual Crossmember II to final drive ......................45 Nm
gearbox 01E4 WD. Crossmember II to crossmember I .............. 45 Nm
Crossmember I to body ............................... 45 Nm
Allocation=> Technical Data, page 00-7 Rear suspension to crossmember ............... 50 Nm
Bracket for metering pump to body ............. 25 Nm
Clip for fuel filter to body .... .......................... 10 Nm
Drive shaft to rear final drive ......... .............. 80 Nm
Trapezium arm to crossmember .................. 85 Nm
Bracket for right handbrake cable to final
drive ............................................................. 25 Nm
Bracket for left handbrake cable to final
drive ........................ ..................................... 25 Nm
Cover plate for drive shaft to fi nal drive ...... . 25 Nm
Closing part to crossmember I .................... 55 Nm
Propshaft to rear final drive ......................... 55 Nm
Cover plate of fuel tank to body ................... 20 Nm
Double pipe clip to exhaust system .......... .. .40 Nm
Tightening torque of wheels ............... ........ 110 Nm

- Code letters and date of manufacture of rear final

drive - up to 02.92 (arrow 1).

Example: AXZ 13 08 1

I I I
Code letters Day Month Year
I
(1991)
of manufacture
..

00-5 39-59

- Code letters and date of manufacture of rear final

drive - from 02.92 (arrow 2).

Example: AXZ 08 03 2

I I
Cocje letters Day
I
Month
I
Year
(1992)
of manufacture

OCH>
~ - Unscrew crossmember II from crossmember I Code letters, allocation, ratios, capacities
(arrows).

- Tie up crossmember I. Rear final drive

Code letters AXZ

-
Manufactured from 01.90
to

Allocation Type/Model Audi VB 1991 ...

3.61-184 kW
Engine: 8-cylinder 3.61-184 kW*)
Vengine 4.2 1-206 kW

Ratios Final drive 37:9=4.111

Z2: Z1 = i
~ - Unscrew crossmember II from final drive (arrows)
and guide away beyond the flange of the final Capacity 1:7 1
drive.
Specification Gear oil GL 5 SAE 90
- Slowly lower final drive complete at front with rear (MIL-L 21058)
gearbox support.
Drive shaft flange dia. 108 mm
Note:
Allocation Manual gearbox CBM
When lowering the final drive, at the same time pull (code letters) CBN
away to the left from the fuel tank.
Remarks *) Switzerland

- Lift final drive out of rear axle beam with gearbox

support and securing bolt.

39-57 00-7

Installation Power transmission diagram

Installation is performed in the reverse order. Pay Designation

attention to the following points:
1 2 3 A2 1 - Engine
Notes: 2 - Clutch
3 - Gearbox
0
• It is important to clean any residues of locking fluid 4 - Input shaft (main shaft) .
from the tapped holes in the flanged shaft for the 5 - Front differential
propshaft of the rear final drive before installing 6 - Front drive pinion (output shaft)
the propshaft. The holes can be cleaned with a 7 - Hollow shaft
thread tap. 8 - Torsen differential
• Always fit new self-locking nuts. 9 - Propshaft
• Always replace gaskets between flanged and 1O - Rear drive pinion
drive shafts as well as the propshaft and rear final 11 - Torsen differential - rear final drive
drive => page 39-11, item 4 (pull off protective
sheet and stick gasket into flanged shaft). Ratios
~. When installing the propshaft, ensure that the
marking points of the flange of the propshaft I - 1st gear
(arrow A) and of the flanged shaft of the rear final II - 2nd gear
drive (arrow 8) are aligned. Ill- 3rd gear
• After installing, adjust propshaft => page 39-18. IV- 4th gear
• Always replace double pipe clip when installing V - 5th gear
exhaust system. 4 7 8 9 10 11 VI- 6th gear
R - Reverse

• •
Align exhaust system free of tension
=> Repair Group 26-8-Cyl. Fuel Injection Engine, A1 - Front final drive
Mechanics. A 2 - Rear final drive
• Check oil level in final drive, add oil if necessary. • T - Speedometer drive (electronic)
- Capacity and specification => page 00-7. Arrows -face in direction of travel

135 - 1362 1
39- 58 00-8
 ._ - Unscrew bracket for metering pump {only on
Calculation of transmission ratio vehicles with auxiliary heater).
Example:

6th gear Final drive

Driving gear ZG 1 = 41 ZA1 = 8

Driven gear ZG2 = 23 ZA2 = 31

Z2 No. of teeth driven gear

i = -- =- - - - - - - - -
z1 No. of teeth driving gear

z~ 23
.ia = Gear ratio = - = - =0.561 ._ .- Slacken clip for fuel filter and move filter in direc-
ZG, 41 tion of arrow (as far as the fuel fee<;i pipe permits).
ZA2 · 31
iA = Axle ratio =- = - =3.875
ZA1 8

i101• = Total ratio = ia x iA

23 31
= - x - =2.134
41 8

00-9 3~55

Notes regarding output test, brake test ._ - Rear suspension: .

and towing vehicle Unscrew nut - A-.

~ Special Information Bulletin " PowerTransmission" - Support final drive with gearbox jack V.A.G 1383A
No.8. and V.A.G 1359/2.

- Secure final drive with strap.

- Pull handbrake cables carefully forward through

the eyes of the crossmember II.

._ - Slacken bolt (arrow A) for crossmember I.

- Unscrew bolt {arrow B) for crossmember I and

carefully lower crossmember I with gearbox jack.

00-10 3~56
~ - Unscrew right-hand bracket of handbrake cable General repair instructions
from final drive (arrows).
The maximum possible care and proper tools are
essential requirements for performing proper and
successful gearbox repairs. The generally applica-
ble basic rules of safety naturally also apply to repair
work.

A number of generally applicable notes for individual

repair operations are summarized here. They apply
to this Workshop Manual.

Gearbox

• When replacing the gearbox or final drive, fill with

gear oil.
Capacity and specification~ page OQ-4 and 00-7.

• When installing gearbox, ensure the dowel sleeves

are correctly seated .
.....,. - Detach handbrake cable at right brake caliper
(arrows). . Gaskets, seals
• Thoroughly clean mating surfaces beforehand.
Note: • Replace paper gaskets.
• Replace 0-rings.
When detaching the handbrake cable, ensure that
the plastic sheathing of the handbrake cable is not
damaged.

00-11
3~53

• .Radial shaft seals

....... - Press handbrake cable out of fixture (arrow A).
Before installing:
- Unscrew right trapezium arm from crossmember - Lightly oil outer diameter.
(arrow B) and carefully lower with gearbox jack - Pack the space between the sealing lips with
V.A.G 1383A and small vehicle jack support. grease.
- Unscrew drive shaft and place down (arrow C). After installing:
- Check oil level; top up any oil loss. Capacity and
specification~ page 00-4 and 00-7.

Sealant
• Thoroughly clean mating surf(lces and apply
sealant AMV 188 200 03.
• Apply an even coat -not too thick- of sealant.
- Keep vent holes clear.

Locking elements
• Replace circlips.
• Do not over-tension circlips.
.....,. - Unscrew handbrake cables at body (arrows). • Circlips must be properly seated in the base of the
groove .

.....,. • .Replace tensioning sleeves.

Installation position: Slot longitudinal to flow pat-
tern.

• Roll pins· (used from 01 /92 in place of tensioning

sleeves)
Installation position: indpendent of force pattern.

00-1 2
3~54
Note: - - Unscrew left bracket of handbrake cable from
final drive (arrows).
Tensioning sleeve or roll pin for attaching 5th/6th
speed selector fork/selector rail must only be re-
moved and inserted with the special tool.

Nuts, bolts

• Slacken and tighten nuts and bolts for securing

covers and housings diagonally.
- Do not twist particularly sensitive parts -e.g.
clutch pressure plates-and slacken and tighten
in stages diagonally.
• Tightening torques are indicated for non-oiled
nuts and bolts.
• Always fit new self-locking nuts and bolts.
- - Detach spring for brake pressure regulator (ar-
Note: row) (only on vehicles without self-levelling sus-
pension).
Clean any residues of microencapsulation from
tapped holes into which self-locking bolts or bolts
inserted with sealant are screwed in. If not, there is
a risk of the bolts seizing when screwed in and
shearing off when removed again. The tapped holes
can be cleaned with a thread tap.

00-13
39-51

Bearings
• Place needle bearings in position with the in-
- - Detach handbrake cable at left brake caliper
scribed side (thicker metal) facing the insertion (arrows).
drift.
• Grease needle bearings for the input shaft in the Note:
crankshaft.
• Oil all bearings in the gearbox with gear oil before
When detaching the handbrake cable, ensure that
inserting. Oil particularly carefully for measuring
the plastic sheathing of the handbrake cable is not
friction torque. damaged.
• Heat inner races of taper roller bearings to approx.
100°C for installing; when fitting , press in as far as
the stop with zero axial play.
• Do not mix up outer and inner races of equal sized
bearings. Bearings are matched.
• Replace all taper roller bearings which are fitted to
the same shaft and use the same makes.

Shims
• Measure shims at several points with a microm-
eter. Different tolerances enable the required
shim thickness to be precisely gauged.
• Check for burrs or signs of damage. - - Unscrew left trapezium arm from crossmember
• Install only shims which are in perfect condition. (arrow A) and lower with gearbox jack V.A.G 1383A
and small vehicle jack support.

- Press handbrake cable out of the fixture (arrow B) .

- Unscrew drive shaft and place down (arrow C).

00-14
39-52
 Synchronizer rings
- - Remove heat insulation plate in front of cross-
• Do not mix up.
member I (arrows).
When re-using, allocate again to the same gear-
wheel.
• Check for signs of wear, replace if necessary.
• Lubricate with gear oil before inserting. ·

Clutch mechanism
Take out clutch slave cylinder without separating the
piping system when removing the gearbox. Do not
operate clutch pedal any more after removing the
. slave cylinder otherwise the piston will be pressed
out of the slave cylinder and rendered unusable.

- - Slacken securing screws of propshaft at rear final

drive after marking position of flange -A- relative ·
to rear final drive-B-in colour if no marking points
are provided.

- Unscrew propshaft and tie up.

Important!

Tie up propshaft only as much as is necessary

to remove the final drive.

00-15
39-49

- - Remove closing part (arrows). Gears, synchronizer bodies, inner

races for selector gears
• When installing, press in as far as the stop with
zero axial play.
• Heat gears to approx. 120°C befqre pressing on.
• Heat inner rings for selector gears to approx.
80°C before pressing on·.

Selector gears

After installing
• 1st to 4th speed selector gears
check for axial play of 0.15 to 0.35 mm .
• 5th and 6th speed selector gears
check that they move freely when rotated.

- - Unscrew cover plate for left drive shaft (arrows).

00-16
39-50
 Servicing clutch mechanism
Removing and installing rear final drive
List of operations Removal
1 4 5 6 7
Pedal cluster - Take off rear wheels.
(Vehicles with 3'.6 litre engine)
...... - Separate exhaust system at double pipe clip.
Note:
- Detach main and final silencers from retaining ,
Grease all bearing points with white solid loops.
lubricating paste, PartNo.AOS 126000 005,
before installing.

Important!

The travel of the brake pedal must not

be shortened by additional floor cover-
ings.

1 - Cable clip
• Hold the feed hose to the pedal
bracket
17 ...... - Unscrew heat shield at the separation point of the
exhaust system (arrows), only slacken both front
16 nuts {left in figure).

13 20 14 12 15 11
l 30-427 I 30-1
39-47

2 - Feed hose
• Lay at pedal bracket accordingly
and secure with cable clip ...... - Remove cover plate of fuel tank (arrows).

1 4 5 6. 7 Important/

Feed hose for master cylinder must not

touch over-centre spring.

3 - Self-locking nut, 20 Nm
• Always replace

4 - Pedal bracket

5 - Return spring for brake pedal

• Attach with the long leg to the pedal
bracket and with the short leg to the
brake pedal

19 6 - Brake pedal
• Fit onto the shaft of the pedal bracket ...... - Remove- heat. insulation plate behind cross-
18 • Is supplied as service part with in- member I (arrows).
jection-m ou Ided bearing bush.
17 Bearing bush cannot be replaced

16

13 20 14 12 15 11
I30-427 I
30-2
39-48
- Secure flanged shaft with hex. socket screw.
7 - Locking element
Note: • Always replace
• Fit onto the shaft of the pedal bracket
Before installing the flanged shaft, insert shims. 1 4 5 6 7
8 - Combination nut, 20 Nm
- Replace gasket between drive shaft and ·flanged
shaft (pull off protective sheet and stick gasket 9 - Brake light switch
onto the joint) . • Always replace
• Press into the fitted clip
- Install drive shaft. • Adjust with clevis attached:
- Operate brake pedal
- Bolt trapezium arm onto crossmember. -: Press in brake light switch as far
as the stop
- Attach spring for brake pressure regulator (only - Pull back brake pedal as far as the
on vehicles without self-levelling suspensiQn). stop by hand

Note:
Note:

Checking and adjusting brake pressure regulator Adjusting clevis for brake pedai => Repair
=> Repair Group 47.:.. Running Gear. . Group·46, Running Gear.

- .Attach handbrake cable to brake caliper. 18

- Press handbrake cable into fixture. 17
~ Install cover plate for drive shaft. 16 -~

13 20 14 12 15 11
39-45 I30-427 I
30-3

- Install exhaust system (main and final silencers). 10 - Air admission valves for cruise
control system
Notes: • Always replace
1 5 6 7 • Press into the fitted clip
• Always fit new double pipe clip. • Adjust with clevis attached:
• Align exhaust system free of tension => Repair .- Operate brake or clutch pedal
Group 26 - 8-Cyl. Fuel Injection Engine, Me- - Press in air admission valves as
chanics. far as the stop
- Pull back brake or clutch pedal as
- Check oil level in final drive, correct if necessary. far as the stop by hand
• Capacity and s p ecificati on ~ page 00-7.
11 - Clips for air ~dmisslon valves of
Tightening torques: cruise control system and for brake
light switch
Hex. socket screw of flanged shaft ... ........... 1o Nm • Press into holes provided in pedal
· and torque a further 90° b~acket as far as the stop using
Drive shaft to flanged shaft .......................... 80 Nm phers.
Trapezium arm to crossmember ..................85 Nm
• Always fit new self-locking nut · 12 - Lock nut, 10 Nm
Cover plate for drive shaft ........................... 25 Nm • Tighten after adjusting clevis
Double pipe clip to exhaust system ........ .....40 Nm
• Always replace · 13 - Screw, 20 Nm
~ Screw master cylinder onto pedal
bracket
17
16 --/'

13 20 14 12 15 11
39-46
l30-427 I 30-4
 14 - Master cylinder - - Unscrew trapezium arm from crossmember (ar-
• Replace if leaking row A) and lower with gearbox jack V.A.G 1383A
• Adjusting clevis=> page 30-7 and small vehicle jack support.
1 4 5 6 7 - Press handbrake cable out of the fixture (arrow B).
15 - Pin
• Attach clevis to clutch pedal I

- Unscrew drive shaft (arrow C).

16 - Clutch pedal
• Can be replaced with pedal bracket - Place oil drip tray below.
. installed
• Is fixed in position by adjusting the
clevis
• Fit onto the shaft of the pedal bracket
• Is supplied as service part with injec-
tion-moulded bearing bush. Bearing
bush cannot be .replaced

17 - Locking element
• Always replace
• Fit onto the shaft of the pedal bracket - - Unscrew flanged shaft.

18 - Pull out flanged shaft at the screwed-in screws.

17 Note:
16-~ Do not lose shim between flanged shaft and differ-
ential.

13 20 14 12 15 11
I30-427 I 39-43
30-5

18 - Over-centre spring - - Lever out seal with assembly bar.

1 4 5 6 7
• Grease at the bearing points of the
bearing journals with white lubricat-
ing paste before assembling
• Removing and installing
=>page 30-8
/ - Thoroughly clean seat of seal.

19 - Locking element
• Always replace
• Fit onto the bearing journal

Note:

Does not need to be removed in order to take

out the over-centre spring.

20 - Locking element
• Always replace
• Fit onto pin
- - Screw threaded rod - A- from assembly device
3066 into the differential.

Notes:
17
• Lightly oil outer diameter of seal.
16 • Pack space between the sealing lips with univer-
sal grease.
• Open side of seal faces final drive.

- Fit seal onto the thrust plate 3066/1 and pull in as

far as the stop with the hex. nut from 306611 .

13 20 14 12 15 11
130-427 I 39-44
30-6
 Replacing oil seal for left flanged shaft - Fig. 1 Adjusting clevis

(Final drive installed) Size "a" = 109.5 ± 0.5 mm

- - Separate exhaust system at double pipe clip. - Turn clevis accordingly for adjusting.

- Detach main and final silencers from retaining Note:

loops.
When measuring, the clevis must be at right angles
to the contact surface of the clutch master cylinder.

Important!

If the clutch pedal does not return by itself with

the clevis correctly adjusted, this may be
caused by:
• Air in the hydraulic system.
• The pedal in its mounting or the over-centre
spring being stiff.

- - Remove cover plate for drive shaft (arrows).

39-41 30-7

- - Detach handbrake cable at left brake caliper Removing and installing over.:centre
(arrows). spring
Note:
Note:
When detaching the handbrake cable, ensure that
the plastic sheathing of the handbrake cable is not Remove the following parts before removing and
installing the over-centre spring:
damaged.
• Left stowage compartment
=> Repair Group 70, General Body Repairs.
• Left legroom air vent
=> Repair Group 80, General Body Repairs.

- Use the assembly clip 3246 for removing and in-

stalling the over-centre sprrng:
- Push assembly clip sideways over the over-cen-
- - Detach spring for brake pressure regulator (ar- tre spring.
row) (only on vehicles without self-levelling sus- - Depress clutch pedal and remove over-centre
pension). spring together with assembly clip.
- Installation is performed in the reverse order.

Notes:

• The assembly clip has been shown with the pedal

bracket removed to simplify the illustration.
• Before assembling, grease the· bearing journals
with white solid lubricating paste.

39-42 30-8
 List of operations - - Insert seal for flanged shaft as far as the stop
using 2062.
1 2 4 5 6 7 Pedal cluster
(Vehicles with 4.2 litre engine) Notes:

) Note:

Grease all bearing points with white solid

• Lightly oil outer diameter of seal.
• Pack space between the sealing lips with univer-
sal grease.
lubricating paste, PartNo.AOS 126000 005, • Open side of seal faces final drive.
before installing.
- Secure flanged shaft with hex. socket screw.
Important! - Replace gasket between drive shaft and flanged
shaft (pull off protective sheet and stick gasket
The travel of the brake pedal must not onto the joint).
be shortened by additional floor cov- - Install drive shaft.
erings. - Bolt trapezium arm to crossmember.
- Attach handbrake cable to brake caliper and
1 - Cable clip press into fixture.
• Hold ·the feed hose to the pedal - Install cover of fuel tank.
bracket - Check oil level in final drive, correct if necessary.
• Capacity and specification==? page 00-7.

10

13 12 11 .
130-4281
30-9
39-39

2 - Feed hose Tlghtenlng torques:

• Lay at pedal bracket accordingly and
secure with cable clip Hex. socket screw of flanged shaft ............~ .10 Nm
1 2 4 5 6 and torque a further 90°
Important! Drive shaft to flanged shaft .......................... 80 Nm
Trapezium arm to crossmember .................. 85 Nm
Feed hose for master cylinder must not • Always fit new self-locking nut
touch over-centre spring. Cover plate of fuel tank to body ................... 20 Nm

3 - Self-locking nut, 20 Nm
• Always replace

4 - Pedal bracket

5 ..:. Return spring for brake pedal

• Attach with the long leg t9 the pedal

I19}) bracket and with the short leg to the

brake pedal

6 - Brake pedal
• Fitontotheshaftofthepedal bracket
18 . • Is supplied as service part with injec-
tion-moulded bearing bush . Bearing
17 bush cannot be replaced
16
10

15
14

13 12 11
130-428 1
30-10 39-40
 Replacing oil seal for right flanged 7 - Locking element
shaft • Always replace
• Fit onto the shaft of the pedal bracket
(Final drive installed) 1 4 5 6
8 - Combination nut, 20 Nm
- - Remove cover of fuel tank (arrows).
9 - Brake light switch
• Always replace
• Press into the fitted clip
• Adjust with clevis attached:
- Operate brake pedal
- Press in brake light switch as far
as the stop
- Pull back brake pedal as far as the
stop by hand

Note:

Adjusting clevis for brake pedal => Repair

Group 46, Running Gear.

- - Detach handbrake cable at right brake caliper

(arrows).

Note: 10
When detaching the handbrake cable, ensur~ that
the plastic sheathing of the handbrake cable is not 15 - -- - - - --'
damaged.
14 ------~~

13 12 11
I30-42a I
.. 39-37 30-11

- - Push handbrake cable out of fixture (arrow A). 10 - Air admission valves for cruise
control system
- Unscrew trapezium arm from crossmember (ar- • Always .replace
row B) and carefully lower with gearbox jack 1 4 5 6 • Press into the fitted clip
V.A.G 1383 A and vehicle jack support. • Adjust with clevis attached:
- Operate brake or clutch pedal
- Unscrew drive shaft and place down (arrow C). - Press in air admission valves as
far as the stop
- Unscrew flanged shaft; secure with drift when - Pull back brake or clutch pedal as
performing this step to prevent it turning. · far as the stop by hand
- Place oil drip tray below. 11 - Clips for air admission valves of
cruise control system and for brake
- Pull out flanged shaft by hand; detach with two, light switch
;:issembly bars, if necessary. • Press into holes provided in pedal
bracket as far as the stop using
pliers
Important!
12..:.. Lock nut, 10 Nm
When levering off flanged shaft, do not dam- • lighten after adjusting clevis
age shoulder on axle housing.
13 - Screw, 20 Nm .
- Leverout oil seal with a suitable tool, e.g. assembly • Screw master cylinder onto pedal
bar. bracket
- Clean seat for seal.
10

13 12 11
39-38 30-12
 - Install heat insulation panels in front of and behind
14 - Master cylinder crossmember II.
• Replace if leaking
- Install heat shield and separation point of exhaust
• Adjusting clevis=> page 30-15 system.
5 6 - Install exhaust system (main and final silencers)
15 - Bolt, 20 Nm
• Always replace double pipe clip.
• Attach clevis to clutch pedal - Add gear oil
• Capacity and specification=> page 00-7.
16 - Clutch p~dal .
• Can be replaced with pedal bracket Notes:
installed
• Is fixed in position by adjusting the
• It is essential to clean any residues of locking fluid
clevis
from the tapped holes in the flanged shaft for the
• Fit onto the shaft of the pedal bracket
propshaft of the rear final drive before installing
• I~ supplied as service part with injec-
the propshaft. The tapped holes can be cleaned
tion-moulded bearing bush. Bearing
with a thread tap.
bush cannot be replaced
• A lways fit new self-locking nuts and bolts.
17 - Locking element • Align exhaust system free of tension => Repair
~roup 26 - 8-Cyl. Fuel Injection Engine, Mechan-
• Always replace
• Fit onto the shaft of the pedal bracket
ics.

18·- Over-centre spring

• Marked in yellow
• Grease at the bearing points of the
bearing journals with white lubricat-
16 ing paste before assembling
10 • Removing and installing
=> page 30-16
15 _ __ __ _...:_,,
1 4 - - - - - --

13 12 11
130-428 I .. 39-35 ·
30-13

19 - Locking element Tightening torques:

• Always replace
• Fit onto the bearing journal Cover. to rear final drive ............................... 25 Nm
1 3 4 ·s 6 Crossmember II to rear final drive ............... 45 Nm
Crossmember I to crossmember II ......... .... .45 Nm
Note:
Crossmember I to body .. .......... .. ................. 45 Nm
Does not need to be removed in order to take Bracket for metering pump to body ............. 25 Nm
out the over-centre spring. Clip for fuel filter to body .............................. 1O Nm
Propshaft to rear final drive ......................... 55 Nm
20 - Locking element Closing part to crossmember I .................... 55 Nm
• Always replace Cover of fuel tank to body ... ................. .......20 Nm
• Fit onto pin Double pipe clip to exhaust system ............ .40 Nm

Note:

Does not need to be removed in order to take

out the over-centre spring.

21 - Over-centre spring
• Marked in white
• Grease at the bearing points of the
bearing journals with white lubricat-
ing paste before assembling
• Removing and installing
=> page 30-16
10

13 12 11
I3o-42a I 39-36
30-14
 Installation - Fig. 1 Adjusting clevis

- - Fit new seal -8- with a washer -A-, Size "a" = 109.5 ± 0.5 mm
Part No. 016 311 391 B (thickness 1.7 mm), onto
insertion drift 2005. - Turn clevis accordingly for adjusting.

Notes: Note:

• Thoroughly clean seat of seal. When measuring, the clevis must be at right angles
• Lightly oil outer diameter of seal. to the contact surface of the clutch master cylinder.
• Pack space between the sealing lips with univer-
sal grease.
• Open side of seal faces final drive. Important!

If the clutch pedal does not return by itself with

the clevis correctly adjusted, this may be
caused by:
• Air in the hydraulic system.
• The pedal in its mounting or the.over-centre
- - Insert seal as far as the stop. spring being stiff.
• The over-centre spring being fitted on
2005 - Take off insertion drift and washer-A-=> top Fig. wrongly.

39--33 30- 15

- - Press in flanged shaft (with plastic washer => Removing and installing over-centre
page 39--23, item 8). spring
- Fit on small circlip.
- Fit on sleeve and drive on with a plastic hammer. Note:
- Insert cover (with new 0-ring) and flanged shaft
into rear axle housing and screw tight. Remove the following parts before removing and
- Screw crossmember II onto final drive. installing the over-centre springs:
- Screw crossmember I onto crossmember II and • Left stowage compartment
body. => Repair Group 70, General Body Repairs.
- Attach bracket with metering pump (only for ve- • Left legroom air vent
hicles with auxiliary heater}. => Repair Group 80, General Body Repairs.
- Push back fuel filter and tighten clip.
- Attach handbrake cables to compensating bar. - Use the assembly clip 3246 for removing and in-
- Attach bracket with handbrake cables. stalling the over-centre springs:
32-109 - Adjust handbrake - Push assembly clip sideways over the over-centre
=> Repair Group 46 - Running Gear. spring.
- Bolt on propshaft, ensuring that the marking points - Depress clutch pedal and remove over-centre
on the flanges of the propshaft and of the rear final spring together with assembly clip.
drive are aligned => page 39--26, Fig. 39-1840. - Installation is perfo.rmed in the reverse order.
- Adjust propshaft => page 39-18.
- Screw on closing part (support for exhaust system).
- Install cover of fuel tank. Important!

3246 When installing, pay attention to coloured

marking of over-centre springs => page 30-13
and30-14.

Notes:

• The assembly clip has been shown with the pedal

bracket removed to simplify the illustration.
• Before assembling, grease the bearing journals
with white solid lubricating paste.

39--34 30-16
 Servicing clutch - - Unscrew cover of final drive and pull out.

Note: A - Headles·s set screw M8/M10

1 2 3 4 For performing work on the clutch, remove
gearbox==? page 34-1.

1 - Flywheel
• Removing and installing
~ Workshop Manual
Audi 100 1991 ~
Repair Group 13-5-Cyl. Fuel Injec-
tion Engine (4-Valve)
• Removing and inserting needle
bearing in flywheel
' ~ Workshop Manual
Audi 100 1991~
Repair Group 13-5-Cyl. Fuel Injec-
tion Engine (4-Valve)

Notes: - - Press off sleeve.

VW 408a
• Ensure the centering pins are tightly - Take off small circlip.
seated.
• Contact surface for clutch lining must be
free of scoring, oil and grease.

30-17 39-31

2 - Clutch plate
• Centering ~ Fig. 1 - - Press out flanged shaft.
• Pay attention to installation position,
1 2 3 4 spring cage faces pressure plate
• Do not grease

Note:

Clean splines of input shflft and, if clutch

plates used, splines of hub. Remove corro-
sion and apply only a verjt thin film ofgrease·
G 000 100 to the splines of the input shaft.
After this, move clutch plate back and for-
ward on the input shaft until the hub moves
freely on the shaft.
Always remove excess grease.

• Diameter of clutch plate

~ Technical Data, page OQ-4

- - Remove seal with VW 681 .

Important!
- Thoroughly clean seat of seal.
Before replacing clutch plate, pay at-
tention to Fault Finding No. 9- faults at
clutch and clutch mechanism.
..

30-18
39-32
• 3 - Pressure plate
..... - Remove bracket for metering pump (only on • Removing and installing ~ Fig. 1
I
: vehicles fitted with auxiliary heater). • Checking ends of diaphragm spring
I
• - Support final drive with gearbox jack V.A.G 1383 1 2 3 4 ~Fi g.2

A and V.A.G 1359/2.

Important!
- Attach final drive with strap.
Pressure plates are protected against
- Carefully pull handbrake cables through eyes of corrosion and greased. They may only
crossmember II to the rear. be cleaned at the contact surface oth-
erwise the life of the clutch will be.
considerably reduced.

Before replacing the pressure plate,

pay attention to Fault Finding No. 9 -
faults at clutch and clutch mechanism.

4 - Screw, 25 Nm

..... - Slacken bolt (arrow A) for crossmember I.

- Unscrew bolt (arrow B) for crossmember I and

carefully lower final drive with gearbox jack.

30-1 9
39-29

..... Fig. 1 Removing and Installing clutch

..... - Unscrew crossmember II from crossmember I
(arrows). - Slacken and tighten screws in stages diagonally,
25Nm.
- Tie up ~rossmember I. • Change over counter-holder 10-201 when re
moving.
• The clutch plate is centred with the guide ·drift
3176. .

Important!

pressure plate must be resting properly on

flywheel all round. Do not Insert securing
screws unless this is the case..On no account,
counter-pull on pressure plate otherwise the
centering holes of the pressure plate and the
centering pins ofthe flywheel wlll be damaged.

..... Fig. 2 Checking ends of diaphragm spring

..... - Unscrew crossmember II from final drive (arrows)
and pull off beyond the flange of the final drive. Wear is permissible up to half the diaphragm spring
thickness. ·

Important! ·

When performing repairs, always match clutch

pressure plate and driven plate on the basis of
the chassis number according to the parts
catalogue.

30-20
39-30
 Fig. 3 Checking spring connection between
pressure plate and cover for cracking, ....,. - Remove closing part (arrows).
checking rivet fasteners are tight

....,. Clutches with damaged or loose riveted joints (ar-

rows) should be replaced.

....,. - Remove securing screws of propshaft at rear final

drive.

- Tie up propshaft.

Important!

Tie up propshaft only sufficiently as is nec-

essary to remove the output flange (universal
joint of propshaft may be damaged).

30-21
39-27

...... - Remove holder for handbrake cables (arrows).

- Slacken adjusting nut for handbrake cables and

detach cables at the compensating bar
=> Repair Group 46 - Running Gear.

...... - Slacken clip for fuel filter and move filter in direc-
tion of arrow (as far as fuel feed pipe permits) .

..

39-28
 Removing and installing gearbox
• - - Remove heat insulation plate behind cross-
I member I (arrows).
=
l
Removal
• Note:

Pay attention to radio coding (determine radio code

by asking customer before disconnecting battery).

- Disconnect earth strap from battery (below rear

seat).
- Take off front wheels.
- - Remove stabilizer bar (arrows).
- Unscrew bracket for left and right air guide pipe
(arrow).

- - Remove heat insulation plate in front of cross- - - Unscrew top part of air cleaner housing (4 screws
member I (arrows). on housing, 3 screws at rear of housing).

..

34-1
39-25

- - Unscrew bottom part of air cleaner housing (ar-

- - Remove cover of fuel tank (arrows) . rows), push back and then lift out and up. ·

- Place oil-drip tray below and drain oil in final drive. Note:

Nuts are self-locking - always replace.

'

- - Remove securing plate of ignition cable holder

- - If no marking points are provided, mark position of (arrows).
flange (arrow A) relative to rear final drive (arrow
B) in colour. Note:

Securing screws are self-locking - _

always replace.

34-2
39-26
 - Unscrew left and right distributor caps (wiring 5 - Cover with grooved ball bearing and
. remains connected). large circlip
....,. - Secure both distributor caps to breather hose of 6 - Countersunk-head screw, 25 Nm
crankcase with cable straps. (2 off)
1234 5 6 7 8 9 7 - Seal

8 - Plastic washer

9 - Flanged shaft
• Pay attention to position relative to
propshaft, mark if necessary
• Replace gasket between flanged
shaft and propshaft (take off protec-
tive sheeting and stick gask~t onto
flanged shaft) .

....,. - Unscrew top engine/gearbox connection bolts

(arrows).

34-3 39-23

..... - Unscrew air guide ring for viscous fan (arrows).

Sequence of operations
- Pull air guide ring up so that it jumps out of the
bottom of the guide. Removal

- Place air guide ring on fan wheel. ....,. - Separate exhaust system at double pipe clip.

' - Detach main and tail silencers from retaining

loops.

..... - Unscrew securing bolts for engine mount/right

top support at body (arrows).
....,. - Unscrew heat shield at separation point of ex-
haust system (arrows); only slacken both front
nuts (left in figure).

34-4
39-24
 ....,. - Centre propshaft; the centre bearing must be
• B C A positioned between the markings {arrow C). ...... - Attach supporting device V.A.G 10-222A into the

~
left engine suspension and take up weight of
- Tighten centre bearing and calcµlated size of engine with the spindle.
• shims to body. ·

- Take off fitting device.

- Screw on heat shield below the propshaft.

- Install exhaust system.

Note:

Align exhaust system free of tension => Repair Group

26 - 8-Cyl. Fuel Injection Engine, Mechanics.

- Install front crossmember below exhaust system.

Tightening torques:
....,. - Remove noise insulation panel {arrows).
Centre bearing for propshaft to body ........... 20 Nm
Catalytic converter to front exhaust pipe ..... 25 Nm
Catalytic converter to suspension strap ...... 25 Nm
Front crossmember to body ........................ 1O Nm

. ..

39-21
34-5

Replacing seal for flang·e/ ...... - Unscrew crossmember {arrow) from body.
propshaft at rear final drive
{Final drive installed)

123456 7 8 9 Note:

Oil seal can only be replaced with final drive

lowered.

Sequence of operations ~ page 39-24

1 - Rear final drive

2 - 0-ring
• Always replace

3 - Sleeve
...... - Unscrew lambda probe {arrow 1) and thermo-
4 - Small clrclip sensor {arrow 2).

- Carefully bend up retaining clip {on left and right

of. gearbox housing) for cables of lambda probe
and thermosensor and take out electric wiring.

139-1847 I 39-22 34-6

 - - Unscrew securing bolts for catalytic converter at - - Unscrew the heat shield below the propshaft
suspension straps (arrow 1) and collar nuts of (arrows).
front exhaust pipe at exhaust manifold (arrow 2).
- Slacken securing bolts of the centre bearing.
- Detach main and tail silencers from retaining
loops. ..

- - Attach fitting device 3139 and tighten plastic nuts.

- - Unscrew shield from closing cover (arrows).
- Take out securing screws and shims of the centre
bearing.

34-7 39-19

- - Remove heat shield below propshaft (arrows). - - Measure clearances "a" -they must be identical
on the left and right- and determine the thickness
- Remove propshaft ::::} page 39-10. of the necessary shims according to the table
below.
- Engage 3rd gear, unscrew clamp for torque and
selector rod ::::} Workshop Manual Audi 100 1991.,. Shims
Repair Group 30 - 5- and 6-Speed Manual Gear- , Clearance Thickness Part No
box 01 E. "a" (mm) (mm)

0 w •• • 3 -
3.1 ... 5 2 857 521 143
5.1 ... 7 4 857 521 143 A
7.1 ... 9 6 857 521 143 B
9.1 ... 11 8 857 521 143 c
11.1 ... 13 10 8575211430

B C A - - Centering propshaft in longitudinal direction.

- Push propshaft back as far as the stop with the

- - Slacken securing sc~ew (arrow D) for angle bracket fitting device.
o_t oil pressure pipes (feed and return, at rear).
- Mark position of centre bearing at body (arrow A) .
- Unscrew securing screw at oil pump cover (arrow
B) for angle bracket of oil pressure pipe (return, at - Push propshaft toward with the fitting device.
rear).
- Mark position of centre bearing on body (arrow B).
- Unscrew banjo bolt (arrow A) at closing cover for
oil pressure pipe (return, at rear) and seal hole
with plug.

- Unscrew banjo bolt at oil pump cover (arrow C) for

oil pressure pipe (feed, ·at rear) and seal hole with
plug.

..
34-8 39-20
•--
Tightening torques .... - Separate oil pressure pipes {front and rear) feed
(arrow 1) and return (arrow 2) and seal with plugs .
Propshaft to gearbox .............. ..... ..... ........... 55 Nm

- Propshaft to rear final drive ......................... 55 Nm

Centre bearing of props haft to body ............ 20 Nm
Shield to closing cover MB ... 25 Nm
· M6 ... 10 Nm
- Unscrew securing bolt (arrow) for angle bracket of
oil pressure pipes (feed and return , at rear) at
engine/gearbox flange.

Catalytic converter to suspension str~p ...... 25 Nm - Unscrew shields of drive shafts.

Catalytic converter to front exhaust pipe ..... 25 Nm
Lambda probe in catalytic converter ...... ..... 50 Nm - Unscrew drive shafts and tie up.
• Grease thread with G5. Hot bearing
grease must not get onto the slot area
of the probe body
Crossmember to body ·············:········· .......... 10 Nm

.... - Detach plug connection of signal cable-1- and of

heater -2- of lambda probe.

- Unscrew fixture of electric wiring -3- from gear-

box housing.

- Unplug connector from speedometer sender

(press down retaining bar for this step) and unclip
electric cable from gearbox housing.

- Unplug connector from gearbox switch for revers-

ing light and unclip electric cable from gearbox
housing (right-hand side).

39-17
34-9

Adjusting propshaft ...... - Unscrew securing bolts (arrows) of gearbox mount

at subframe.
The adjustment operations should be performed
with the greatest care as an incorrectly adjusted
propshaft is frequently the cause of vibrations and
droning noises.

Note:

Work on the camshaft should be performed on a

two-pillar lifting platform.

.... - Remove front crossmember below the exhaust

system (arrow).

- Remove catalytic converters with main and tail

si lencers ~ Repair Group 26 - 8-Cyl. Fuel Injec-
tion Engine, Mechanics.
....,. - Support subframe with gearbox jack V.A.G 1383A
Important! and subframe support V.A.G 1584.
Before removing the exhaust system, unscrew - Unscrew rear securing bolt of subframe (on left
the thermosensor and lambda probe. and right).

- Slowly lower gearbox jack.

Notes:

• When lowering gearbox, ensure that the air guide

ring of the viscous fan and the drive shafts do not
jam.
• The gearbox is lowered further by tightening the
lifting device V.A.G 10-222A.

39-18 34- 10
 - - Unscrew securing bolt -A- for the cable bracket - - Attach fitting device 3139 and tighten plastic nuts.
-8- of the procon-ten system.
- Unscrew securing bolts of propshaft at rear final
- Push cable bracket with the procon-ten cable drive and at gearbox. ·
over the cable guide. ·
- Support propshaft and fitting device and unscrew
- Remove gearbox support together with gearbox securing bolts of centre bearing from body.
mount (on left and right).
- Take out propshaft and fitting device.
A - Remove clutch slave cylinder.

Notes: Important!
• Do not open piping system. Propshaft must only be transported stretched.
• To facilitate removal, swivel the selector lever at
the gearbox into the position of 6th gear.

Important!

Do not operate clutch pedal any more after

removing the slave cylinder.

- Support gearbox with gear~ox jack V.A.G 1383 A.

34-11
39-15

- - Unscrew starter (arrow A) and pull off only suffi- Installation

ciently for it to touch the oil filter.
Installation is performed in the reverse order.
- Unscrew bottom engine/gearbox connecting bolts
(arrows). Notes:

• It is important to clean any residues of locking

' agent from the tapped holes in the flanged shafts
for the propshaft of the gearbox and of the rear
final drive before installing the propshaft.
The tapped holes 9an be <;leaned "!lith a thread
tap. . .
• Always fit new self-locking screws and bolts.
- • When attaching the propshaft, ensure that the
marking points of the flange of the propshaft
(arrow A) and of the flanged shaft of the rear final
drive (arrow 8) are aligned,
• Always fit new gasket between propshaft and
gearbox or rear ·final drive (pull off protective
sheeting and stick gasket to the flanged shaft).
- - Press gearbox off dowel sleeves and carefully
lower with gearbox jack. • After installing, adjust propshaft ~page 39-18.
• 'Align exhaust system free of tension
~ RepairGroup26- 8-Cyl. Fuel Injection Engine,
Mechanics.
Important!

When lowering, ensure clearance to the drive

shafts. · ·

34-12 39-16
-I Sequence of operations ln~ta llation

-
1
Removal

Note:

Work on the propshaft should only be performed on

Installation of t he gearbox is performed in the re-
verse order.

Notes:

a two-co!umn lifting platform. • Check whether the dowel sleeves for centering
engine/gearbox are fitted in the gearbox flange,
insert if necessary => page 34-15.
..... - Remove front crossmember below exhaust sys- • Do not install clutch slave cylinder until gearbox
tem. has been installed
=> Workshop Manual Audi 100 1991 .,..
- Remove catalytic converters with main and tail Repair Group 30 - 5- and 6-Speed Manual Gear-
silencers box 01 E.
=>Repair Group 26-8-Cyl. Fuel Injection Engine, • It is essential to clean the residues of locking
Mechanics. agent from the tapped holes in the flanged shafts
for the propshaft of the manual gearbox and rear
Important!" final drive as well as from the tapped hole for
attaching the clutch slave cylinder with a thread
Before removing the exhaust system, unscrew · tap before installing.
.thermosensor and Jainbda probe. • Always replace gaskets at the connection points
of the propshaft =>page 39'-11, item 4 and drive
shafts.
...,. - Unscrew shield from closing cover (arrows). • Always adjust propshaft => page 39-18
after installing => page 39-16.
• Always adjust selector and torque rod after install-
ing => Workshop Manual Audi 100 1991 .,..
Repair Group 34 - 5- and 6-Speed Manual Gear- .
box 01 E.

39-1 3 34-13

..... - Unscrew heat shield below the props haft (arrows). • Align exhaust system free of tension
=>Repair Group 26 - 8-Cyl. Fuel Injection Engine,
Mechanics.
•· Add oil to manual gearbox.
- Capacity and specification => page 00-4.
• The front axle should be re-aligned after installing
t he gearbox.

..... - If no marking points are provided, mark position of

flange (arrow A) relative to rear final drive (arrow
B) in colour.

- Slacken securing bolts of propshaft at rear final

drive and at the gearbox.
.. .
- Slacken securing bolts of centre bearing .

39-14 34-14
 Tightening torques:

~ - Engine/gearbox attachment (flange diagram en- 3 Important!

1 2
gine)
Do not twist propshaft, store and trans-
Item Bolt Qty. Nm port only stretched.
Use assembly device 3139 => page
1 M12 x 75 3 65 39-15.
2 M12 x 90 1 65
3 M10x 40 1 45
4 M10 x 45 1 45 1 - Gearbox
5 M Bx 45 1 25
6 M10x120 1 45 2 - Propshatt
7 M12 x 110 1 65
3 - Rear final drive

Dowel sleeves for centering items -A- and -8- 4 - Gasket

• Always replace
Clutch slave cylinder to gearbox .... .. ........... 25 Nm • Remove protective sheeting before-
Gearbox support to gearbox housing ........ .40 Nm hand
Cable guide of procon-ten system t0
gearbox ........................... ............................ 40 Nm 5 - Baseplate
Subframe to body ....................................... 65 Nm (3 off)
. and torque a further 90°
• Always replace bolt 6 - Screw, 55 Nm
Gearbox mount to subframe ...................... .40 Nm (6 off)
Drive shaft to flanged shaft .................. ..... .. BO Nm • Always replace
Shield of drive shaft to gearbox .................. 25 Nm

4 5 6 8 7 6 5 4

@9-1841 1
34-15 39-11

Front oil pressure pipe to rear oil pressure 7 - Shim

pipe .............................................................. 40 Nm • Determining thickness
• Always replace 0-ring => page 39-20
Banjo bolt to oil pump cove~ ........................ 25 Nm 1 2 3
• Always replace 0-ring 8 - Bolt, 20 Nm
Banjo bolt to closing cover .......................... 25 Nm (2 off)
• Always replace 0-ring c
Angle bracket of return pipe to oil pump
cover ............................................................ 25 Nm
Angle bracket of rear oil pressure pipes
to engine/gearbox flange ......... .................... 25 Nm
Clamp of selector and torque rod ................ 25 Nm
Propshaft to gearbox/final drive ... ................ 55 Nm
Shield to closing cover MB ... 25 Nm
M6 ... 10Nm
Catalytic converter to suspension strap ...... 25 Nm
Front exhaust pipe to exhaust manifold ...... 25 Nm
Lambda probe in catalytic converter ......... .. 50 Nm
• Grease thread with GS. Hot bearing
grease must not get into the slot area
of the probe body
Crossmember to body ................................. 10 Nm
Torque support to body ........................... .... .40 Nm
Air guide ring of viscous fan toframe of
radiator ........................................................ 10 Nm
Air cleaner housing - bottom part ............... 10 Nm
Air cleaner housing - top part ..................... 1O Nm
Anti-roll bar to suspension strut dome ....... .. 20 Nm
lightening torque of wheels ....................... 110 Nm

r 4 5 6 8 7 6 5 4

34-16 @ 9-18411 39-12

•
 - - Press in flanged shaft. Removing and installing oil pump
•-l
- ~VW407 - Fit circlip onto flanged shaft.

- Lightly oil 0-ring and place into groove of bearing

Removal
(Gearbox installed)
housing.
- - Remove noise insulation panel (arrows).
- Place cup spring and washers into bearing
housing.
• Installation position==> page 39-5, items 8 -9.

- Fit spiral spring onto flanged shaft.

- Tighten securing bolts for bearing housing in

stages diagonally.

- Add gear oil

• Specification ==> page 00-4.
• Ignore additive if slight losses of gear oil.
• Tightening torque of oil drain plug, 35 Nm.
- - Remove crossmember (arrow) from body.

34-17
39-9

Removing and installing

- - Unscrew lambda probe (arrow 1) and thermo-
propshaft sensor (arrow 2).
1 2 3
Sequence of operations ==> page 39-13
Adjusting ==> page 39-18

Notes:

• Work on the propshaft should only be

performed on a two-column lifting plat-
form.
• No repair work - except removal and
installation and adjustment operations -
may be performed on the propshaft.
• Universal joints and bearings cannot be
replaced with workshop equipment.
• Front orrearpropshaft cannot be removed
individually.
• If customer complaints are received
(noises, vibrations), always check whether
proper adjustment of the propshaft recti- - - Unscrew securing bolts for catalytic converter at
fies the fault before replacing t~e propshaft. suspension strap (arrow 1) an~ collar nuts of front
exhaust pipe at exhaust manifold (arrow 2).

- Detach main and tail silencers from retaining

loops.

- Place oil drip tray below and drain gear oil.

4 5 6 8 7 6 5 4

j 39-184 1 l 39-10
34-18
- - Slacken securing bolt (arrow D) for angle bracket . - Take circlip off flanged shaft.

~VW407
of oil pressure pipes (feed and return, at rear).
- - Press out flanged shaft.
- Unscrew securing bolt and oil pump cover (arrow
B) for angle bracket of oil pressure pipe (return, at
rear).

- Unscrew banjo bolt (arrow A) at closing cover for VW295a

oil pressure pipe (return, at rear).

- Unscrew banjo bolt at oil pump cover (arrow C) for

oil pressure pipe (feed, at rear). ·

- Unscrew shield of right drive shaft.

- Unscrew right <;!rive shaft and tie up.

- Unscrew right flanged shaft and remove.

Note:

Dismantling principle of flanged· shaft ~ page

39-43, Fig. 39-1868. .

- Unscrew remaining top securing bolt of oil pump VW681 - - Remove seal for flanged shaft.
cover.
- Thoroughly clean seat of the sealing_ring.
- - Use a suitable tQol (pliers) to grasp oil pump at a
reinforcing rib ofthe oil pump cover and to remove
axially.

34-19
39- 7

Installation Installation

Installation of the oil pump is performed in the - - Fit seal -B- with a washer -A-
reverse order, · =} Part No. 016 311 391 B (thickness 1.7 mm)
onto insertion drift 2005.
Notes:
Notes:
• When inserting the oil pump, ensure that the drive
pinion engages in the drive gear. The oil pump • Lightly oil outer diameter of seal.
cover is resting properly on the housing flange all • Pack space between sealing lips with grease.
round. Always replace 0-ring. • Open side of seal faces gearbox.
• Always replace gasket. between drive shaft and
flanged shaft (pull off protective sheet and stick
gasket onto the joint).
• Align exhaust system free of tension
~Repair Group 26- 8-Cyl. Fuel Injection Engine,
Mechanics. ·
• Add oil to gearbox. Capacity and specification ~
page OD-4.

- - Insert.seal for flanged shaft.

2005
- After !nserting, remove washer -A-:::} top Fig.
VW401

34-20 39-8
-
-
- 7 - Circllp Tlghtening torques:

Oil pump cover to gearbox housing ......... .... 25 Nm

8 - Cup spring
• Mark installation position when re- Hex. socket screw on flanged shaft ............. 10 Nm
1 2 3 and torque a further 90°
moving (concave side faces wash-
ers => item 9) Drive shaft to flanged shaft .......................... 80 Nm
Shield of drive shaft to gearbox ............... .... 25 Nm
9 - Washer Banjo bolt to oil pump cover ........................ 25 Nm
• Always replacE! 0-ring
10 - Spiral spring Banjo bolt to closing cover ........ ..................25 Nm
• Always replace 0-ring
Angle bracket of return pipe to oil pump
cover ............................................................ 25 Nm
Angle bracket of oil pressure pipes at rear
to engine/gearbox flange ........ ......................25 Nm
Catalytic converter to suspension strap .. .... 25 Nm
Front exhaust pipe to exhaust manifold .. .... 25 Nm
Lambda probe in catalytic converter ...........50 Nm
• Grease thread with G5. Hot bearing
grease must not get onto the slot area
of the probe body.
Crossmember to body ................................. 10 Nm
Oil drain plug ... .. ................................... : ......40 Nm

I
10 9 8 7 6 5 4

139-1856 j
34-21
39-5

Sequence of operations
Removal

- Place oil drip tray below and drain gear oil (oil
drain plug at closing cover).

- Unscrew securing bolts => page 39-4, item 5, for

bearing housing.

Note:

Bearing housing is pushed slightly off the closing

cover by the spiral spring when the securing bolts
are slackened. ·

..... - Pull flanged shaft with bearing housing off the

closing cover.

A - Headless set screw M8/M10

- Take off bearing housing, paying attention to

~nstallation position of cup spring => page 39-5,
item 8.

39-6
 Replacing flanged shaft oil seal - Replacing speedometer gear -0-

(Gearbox installed) ...,. - Unscrew drive shaft from left flanged shaft.
- Remove screw -A-. Secure flanged shaft with
Note: drift prevent it turning.
- Remove flanged shaft -B- and seal -C- for
• Removal and installation of left oil seal (figures) flanged shaft.
and right oil seal (not shown) is identical. - Remove speedometer gear-D- with screwdriver
by levering alternately atthe driving studs (arrows).
- Disconnect drive shaft.
- Place oil drip tray below. When installing, pay attention to the following point:
- Remove flanged shaft, secure with drift to prevent - Press speedometer gear-D- onto the differential
it turning . as far as the stop.
...,. - Pull out seal with forcing lever VW 681.
Note:

The dril(ing studs of the speedometer gear (arrows)

face the seal -C- and engage in the slots of the
differential housing.
VW195 ..... - Insert seal for flanged shaft.
- Replace seal -C- for flanged shaft ~ page 39-1 .
Insertion depth= 5.5 mm.
- Install flanged shaft~ page 39-1 .
- Pack space between sealing and dust lips with - Top up gear oil.
universal grease.
• Capacity and specification ~ page 00-4
- Install flanged shaft and drive shaft.
• Ignore additive if minor losses of gear oil exist.
Tightening torques:
'J
Flanged shaft to gearbox ............................. 10 Nm
and torque a further 90°
Drive shaft to flanged shaft .......................... 80 Nm

3.9-1 39-3

Replacing electronic speedometer Replacing seal for flange/

sender and gear propshaft at gearbox
1 2 3 (Gearbox installed)
(Gearbox installed)
Sequence of operations ~ page 39-6

Removing and installing propshaft

...,. - Replacing speedometer sender ..:.B- ~page 39-10

- Unplug connector from sender -8-. l 1 - Gearbox

'
- Press down retaining bar and carefully swing 2 - Bearing housing with balancing
speedometer sender outward without damaging weight and grooved ball bearing
it otherwise the speeds may not be indicated
properly. Note:

- Always replace seal -A- when installing. Balancing weight fitted only to vehicles with
4.2 litre engine.

3 - Seal
4 - Flanged shaft

5 - Torx screw, 25 Nm

6 - 0-ring
1 • Always replace

iJ
l I
10 9 8 7 6 5 4

139-1856 1
39-2 39-4
 Replacing flanged shaft oil seal - Replacing speedometer gear -0-

(Gearbox installed) ...,. - Unscrew drive shaft from left flanged shaft.
- Remove screw -A-. Secure flanged shaft with
Note: drift prevent it turning.
- Remove flanged shaft -B- and seal -C- for
• Removal and installation of left oil seal (figures) flanged shaft.
and right oil seal (not shown) is identical. - Remove speedometer gear-D- with screwdriver
by levering alternately atthe driving studs (arrows).
- Disconnect drive shaft.
- Place oil drip tray below. When installing, pay attention to the following point:
- Remove flanged shaft, secure with drift to prevent - Press speedometer gear-D- onto the differential
it turning . as far as the stop.
...,. - Pull out seal with forcing lever VW 681.
Note:

The dril(ing studs of the speedometer gear (arrows)

face the seal -C- and engage in the slots of the
differential housing.
VW195 ..... - Insert seal for flanged shaft.
- Replace seal -C- for flanged shaft ~ page 39-1 .
Insertion depth= 5.5 mm.
- Install flanged shaft~ page 39-1 .
- Pack space between sealing and dust lips with - Top up gear oil.
universal grease.
• Capacity and specification ~ page 00-4
- Install flanged shaft and drive shaft.
• Ignore additive if minor losses of gear oil exist.
Tightening torques:
'J
Flanged shaft to gearbox ............................. 10 Nm
and torque a further 90°
Drive shaft to flanged shaft .......................... 80 Nm

3.9-1 39-3

Replacing electronic speedometer Replacing seal for flange/

sender and gear propshaft at gearbox
1 2 3 (Gearbox installed)
(Gearbox installed)
Sequence of operations ~ page 39-6

Removing and installing propshaft

...,. - Replacing speedometer sender ..:.B- ~page 39-10

- Unplug connector from sender -8-. l 1 - Gearbox

'
- Press down retaining bar and carefully swing 2 - Bearing housing with balancing
speedometer sender outward without damaging weight and grooved ball bearing
it otherwise the speeds may not be indicated
properly. Note:

- Always replace seal -A- when installing. Balancing weight fitted only to vehicles with
4.2 litre engine.

3 - Seal
4 - Flanged shaft

5 - Torx screw, 25 Nm

6 - 0-ring
1 • Always replace

iJ
l I
10 9 8 7 6 5 4

139-1856 1
39-2 39-4
-
-
- 7 - Circllp Tlghtening torques:

Oil pump cover to gearbox housing ......... .... 25 Nm

8 - Cup spring
• Mark installation position when re- Hex. socket screw on flanged shaft ............. 10 Nm
1 2 3 and torque a further 90°
moving (concave side faces wash-
ers => item 9) Drive shaft to flanged shaft .......................... 80 Nm
Shield of drive shaft to gearbox ............... .... 25 Nm
9 - Washer Banjo bolt to oil pump cover ........................ 25 Nm
• Always replacE! 0-ring
10 - Spiral spring Banjo bolt to closing cover ........ ..................25 Nm
• Always replace 0-ring
Angle bracket of return pipe to oil pump
cover ............................................................ 25 Nm
Angle bracket of oil pressure pipes at rear
to engine/gearbox flange ........ ......................25 Nm
Catalytic converter to suspension strap .. .... 25 Nm
Front exhaust pipe to exhaust manifold .. .... 25 Nm
Lambda probe in catalytic converter ...........50 Nm
• Grease thread with G5. Hot bearing
grease must not get onto the slot area
of the probe body.
Crossmember to body ................................. 10 Nm
Oil drain plug ... .. ................................... : ......40 Nm

I
10 9 8 7 6 5 4

139-1856 j
34-21
39-5

Sequence of operations
Removal

- Place oil drip tray below and drain gear oil (oil
drain plug at closing cover).

- Unscrew securing bolts => page 39-4, item 5, for

bearing housing.

Note:

Bearing housing is pushed slightly off the closing

cover by the spiral spring when the securing bolts
are slackened. ·

..... - Pull flanged shaft with bearing housing off the

closing cover.

A - Headless set screw M8/M10

- Take off bearing housing, paying attention to

~nstallation position of cup spring => page 39-5,
item 8.

39-6
- - Slacken securing bolt (arrow D) for angle bracket . - Take circlip off flanged shaft.

~VW407
of oil pressure pipes (feed and return, at rear).
- - Press out flanged shaft.
- Unscrew securing bolt and oil pump cover (arrow
B) for angle bracket of oil pressure pipe (return, at
rear).

- Unscrew banjo bolt (arrow A) at closing cover for VW295a

oil pressure pipe (return, at rear).

- Unscrew banjo bolt at oil pump cover (arrow C) for

oil pressure pipe (feed, at rear). ·

- Unscrew shield of right drive shaft.

- Unscrew right <;!rive shaft and tie up.

- Unscrew right flanged shaft and remove.

Note:

Dismantling principle of flanged· shaft ~ page

39-43, Fig. 39-1868. .

- Unscrew remaining top securing bolt of oil pump VW681 - - Remove seal for flanged shaft.
cover.
- Thoroughly clean seat of the sealing_ring.
- - Use a suitable tQol (pliers) to grasp oil pump at a
reinforcing rib ofthe oil pump cover and to remove
axially.

34-19
39- 7

Installation Installation

Installation of the oil pump is performed in the - - Fit seal -B- with a washer -A-
reverse order, · =} Part No. 016 311 391 B (thickness 1.7 mm)
onto insertion drift 2005.
Notes:
Notes:
• When inserting the oil pump, ensure that the drive
pinion engages in the drive gear. The oil pump • Lightly oil outer diameter of seal.
cover is resting properly on the housing flange all • Pack space between sealing lips with grease.
round. Always replace 0-ring. • Open side of seal faces gearbox.
• Always replace gasket. between drive shaft and
flanged shaft (pull off protective sheet and stick
gasket onto the joint).
• Align exhaust system free of tension
~Repair Group 26- 8-Cyl. Fuel Injection Engine,
Mechanics. ·
• Add oil to gearbox. Capacity and specification ~
page OD-4.

- - Insert.seal for flanged shaft.

2005
- After !nserting, remove washer -A-:::} top Fig.
VW401

34-20 39-8
 - - Press in flanged shaft. Removing and installing oil pump
•-l
- ~VW407 - Fit circlip onto flanged shaft.

- Lightly oil 0-ring and place into groove of bearing

Removal
(Gearbox installed)
housing.
- - Remove noise insulation panel (arrows).
- Place cup spring and washers into bearing
housing.
• Installation position==> page 39-5, items 8 -9.

- Fit spiral spring onto flanged shaft.

- Tighten securing bolts for bearing housing in

stages diagonally.

- Add gear oil

• Specification ==> page 00-4.
• Ignore additive if slight losses of gear oil.
• Tightening torque of oil drain plug, 35 Nm.
- - Remove crossmember (arrow) from body.

34-17
39-9

Removing and installing

- - Unscrew lambda probe (arrow 1) and thermo-
propshaft sensor (arrow 2).
1 2 3
Sequence of operations ==> page 39-13
Adjusting ==> page 39-18

Notes:

• Work on the propshaft should only be

performed on a two-column lifting plat-
form.
• No repair work - except removal and
installation and adjustment operations -
may be performed on the propshaft.
• Universal joints and bearings cannot be
replaced with workshop equipment.
• Front orrearpropshaft cannot be removed
individually.
• If customer complaints are received
(noises, vibrations), always check whether
proper adjustment of the propshaft recti- - - Unscrew securing bolts for catalytic converter at
fies the fault before replacing t~e propshaft. suspension strap (arrow 1) an~ collar nuts of front
exhaust pipe at exhaust manifold (arrow 2).

- Detach main and tail silencers from retaining

loops.

- Place oil drip tray below and drain gear oil.

4 5 6 8 7 6 5 4

j 39-184 1 l 39-10
34-18
 Tightening torques:

~ - Engine/gearbox attachment (flange diagram en- 3 Important!

1 2
gine)
Do not twist propshaft, store and trans-
Item Bolt Qty. Nm port only stretched.
Use assembly device 3139 => page
1 M12 x 75 3 65 39-15.
2 M12 x 90 1 65
3 M10x 40 1 45
4 M10 x 45 1 45 1 - Gearbox
5 M Bx 45 1 25
6 M10x120 1 45 2 - Propshatt
7 M12 x 110 1 65
3 - Rear final drive

Dowel sleeves for centering items -A- and -8- 4 - Gasket

• Always replace
Clutch slave cylinder to gearbox .... .. ........... 25 Nm • Remove protective sheeting before-
Gearbox support to gearbox housing ........ .40 Nm hand
Cable guide of procon-ten system t0
gearbox ........................... ............................ 40 Nm 5 - Baseplate
Subframe to body ....................................... 65 Nm (3 off)
. and torque a further 90°
• Always replace bolt 6 - Screw, 55 Nm
Gearbox mount to subframe ...................... .40 Nm (6 off)
Drive shaft to flanged shaft .................. ..... .. BO Nm • Always replace
Shield of drive shaft to gearbox .................. 25 Nm

4 5 6 8 7 6 5 4

@9-1841 1
34-15 39-11

Front oil pressure pipe to rear oil pressure 7 - Shim

pipe .............................................................. 40 Nm • Determining thickness
• Always replace 0-ring => page 39-20
Banjo bolt to oil pump cove~ ........................ 25 Nm 1 2 3
• Always replace 0-ring 8 - Bolt, 20 Nm
Banjo bolt to closing cover .......................... 25 Nm (2 off)
• Always replace 0-ring c
Angle bracket of return pipe to oil pump
cover ............................................................ 25 Nm
Angle bracket of rear oil pressure pipes
to engine/gearbox flange ......... .................... 25 Nm
Clamp of selector and torque rod ................ 25 Nm
Propshaft to gearbox/final drive ... ................ 55 Nm
Shield to closing cover MB ... 25 Nm
M6 ... 10Nm
Catalytic converter to suspension strap ...... 25 Nm
Front exhaust pipe to exhaust manifold ...... 25 Nm
Lambda probe in catalytic converter ......... .. 50 Nm
• Grease thread with GS. Hot bearing
grease must not get into the slot area
of the probe body
Crossmember to body ................................. 10 Nm
Torque support to body ........................... .... .40 Nm
Air guide ring of viscous fan toframe of
radiator ........................................................ 10 Nm
Air cleaner housing - bottom part ............... 10 Nm
Air cleaner housing - top part ..................... 1O Nm
Anti-roll bar to suspension strut dome ....... .. 20 Nm
lightening torque of wheels ....................... 110 Nm

r 4 5 6 8 7 6 5 4

34-16 @ 9-18411 39-12

•
-I Sequence of operations ln~ta llation

-
1
Removal

Note:

Work on the propshaft should only be performed on

Installation of t he gearbox is performed in the re-
verse order.

Notes:

a two-co!umn lifting platform. • Check whether the dowel sleeves for centering
engine/gearbox are fitted in the gearbox flange,
insert if necessary => page 34-15.
..... - Remove front crossmember below exhaust sys- • Do not install clutch slave cylinder until gearbox
tem. has been installed
=> Workshop Manual Audi 100 1991 .,..
- Remove catalytic converters with main and tail Repair Group 30 - 5- and 6-Speed Manual Gear-
silencers box 01 E.
=>Repair Group 26-8-Cyl. Fuel Injection Engine, • It is essential to clean the residues of locking
Mechanics. agent from the tapped holes in the flanged shafts
for the propshaft of the manual gearbox and rear
Important!" final drive as well as from the tapped hole for
attaching the clutch slave cylinder with a thread
Before removing the exhaust system, unscrew · tap before installing.
.thermosensor and Jainbda probe. • Always replace gaskets at the connection points
of the propshaft =>page 39'-11, item 4 and drive
shafts.
...,. - Unscrew shield from closing cover (arrows). • Always adjust propshaft => page 39-18
after installing => page 39-16.
• Always adjust selector and torque rod after install-
ing => Workshop Manual Audi 100 1991 .,..
Repair Group 34 - 5- and 6-Speed Manual Gear- .
box 01 E.

39-1 3 34-13

..... - Unscrew heat shield below the props haft (arrows). • Align exhaust system free of tension
=>Repair Group 26 - 8-Cyl. Fuel Injection Engine,
Mechanics.
•· Add oil to manual gearbox.
- Capacity and specification => page 00-4.
• The front axle should be re-aligned after installing
t he gearbox.

..... - If no marking points are provided, mark position of

flange (arrow A) relative to rear final drive (arrow
B) in colour.

- Slacken securing bolts of propshaft at rear final

drive and at the gearbox.
.. .
- Slacken securing bolts of centre bearing .

39-14 34-14
 - - Unscrew securing bolt -A- for the cable bracket - - Attach fitting device 3139 and tighten plastic nuts.
-8- of the procon-ten system.
- Unscrew securing bolts of propshaft at rear final
- Push cable bracket with the procon-ten cable drive and at gearbox. ·
over the cable guide. ·
- Support propshaft and fitting device and unscrew
- Remove gearbox support together with gearbox securing bolts of centre bearing from body.
mount (on left and right).
- Take out propshaft and fitting device.
A - Remove clutch slave cylinder.

Notes: Important!
• Do not open piping system. Propshaft must only be transported stretched.
• To facilitate removal, swivel the selector lever at
the gearbox into the position of 6th gear.

Important!

Do not operate clutch pedal any more after

removing the slave cylinder.

- Support gearbox with gear~ox jack V.A.G 1383 A.

34-11
39-15

- - Unscrew starter (arrow A) and pull off only suffi- Installation

ciently for it to touch the oil filter.
Installation is performed in the reverse order.
- Unscrew bottom engine/gearbox connecting bolts
(arrows). Notes:

• It is important to clean any residues of locking

' agent from the tapped holes in the flanged shafts
for the propshaft of the gearbox and of the rear
final drive before installing the propshaft.
The tapped holes 9an be <;leaned "!lith a thread
tap. . .
• Always fit new self-locking screws and bolts.
- • When attaching the propshaft, ensure that the
marking points of the flange of the propshaft
(arrow A) and of the flanged shaft of the rear final
drive (arrow 8) are aligned,
• Always fit new gasket between propshaft and
gearbox or rear ·final drive (pull off protective
sheeting and stick gasket to the flanged shaft).
- - Press gearbox off dowel sleeves and carefully
lower with gearbox jack. • After installing, adjust propshaft ~page 39-18.
• 'Align exhaust system free of tension
~ RepairGroup26- 8-Cyl. Fuel Injection Engine,
Mechanics.
Important!

When lowering, ensure clearance to the drive

shafts. · ·

34-12 39-16
•--
Tightening torques .... - Separate oil pressure pipes {front and rear) feed
(arrow 1) and return (arrow 2) and seal with plugs .
Propshaft to gearbox .............. ..... ..... ........... 55 Nm

- Propshaft to rear final drive ......................... 55 Nm

Centre bearing of props haft to body ............ 20 Nm
Shield to closing cover MB ... 25 Nm
· M6 ... 10 Nm
- Unscrew securing bolt (arrow) for angle bracket of
oil pressure pipes (feed and return , at rear) at
engine/gearbox flange.

Catalytic converter to suspension str~p ...... 25 Nm - Unscrew shields of drive shafts.

Catalytic converter to front exhaust pipe ..... 25 Nm
Lambda probe in catalytic converter ...... ..... 50 Nm - Unscrew drive shafts and tie up.
• Grease thread with G5. Hot bearing
grease must not get onto the slot area
of the probe body
Crossmember to body ·············:········· .......... 10 Nm

.... - Detach plug connection of signal cable-1- and of

heater -2- of lambda probe.

- Unscrew fixture of electric wiring -3- from gear-

box housing.

- Unplug connector from speedometer sender

(press down retaining bar for this step) and unclip
electric cable from gearbox housing.

- Unplug connector from gearbox switch for revers-

ing light and unclip electric cable from gearbox
housing (right-hand side).

39-17
34-9

Adjusting propshaft ...... - Unscrew securing bolts (arrows) of gearbox mount

at subframe.
The adjustment operations should be performed
with the greatest care as an incorrectly adjusted
propshaft is frequently the cause of vibrations and
droning noises.

Note:

Work on the camshaft should be performed on a

two-pillar lifting platform.

.... - Remove front crossmember below the exhaust

system (arrow).

- Remove catalytic converters with main and tail

si lencers ~ Repair Group 26 - 8-Cyl. Fuel Injec-
tion Engine, Mechanics.
....,. - Support subframe with gearbox jack V.A.G 1383A
Important! and subframe support V.A.G 1584.
Before removing the exhaust system, unscrew - Unscrew rear securing bolt of subframe (on left
the thermosensor and lambda probe. and right).

- Slowly lower gearbox jack.

Notes:

• When lowering gearbox, ensure that the air guide

ring of the viscous fan and the drive shafts do not
jam.
• The gearbox is lowered further by tightening the
lifting device V.A.G 10-222A.

39-18 34- 10
 - - Unscrew securing bolts for catalytic converter at - - Unscrew the heat shield below the propshaft
suspension straps (arrow 1) and collar nuts of (arrows).
front exhaust pipe at exhaust manifold (arrow 2).
- Slacken securing bolts of the centre bearing.
- Detach main and tail silencers from retaining
loops. ..

- - Attach fitting device 3139 and tighten plastic nuts.

- - Unscrew shield from closing cover (arrows).
- Take out securing screws and shims of the centre
bearing.

34-7 39-19

- - Remove heat shield below propshaft (arrows). - - Measure clearances "a" -they must be identical
on the left and right- and determine the thickness
- Remove propshaft ::::} page 39-10. of the necessary shims according to the table
below.
- Engage 3rd gear, unscrew clamp for torque and
selector rod ::::} Workshop Manual Audi 100 1991.,. Shims
Repair Group 30 - 5- and 6-Speed Manual Gear- , Clearance Thickness Part No
box 01 E. "a" (mm) (mm)

0 w •• • 3 -
3.1 ... 5 2 857 521 143
5.1 ... 7 4 857 521 143 A
7.1 ... 9 6 857 521 143 B
9.1 ... 11 8 857 521 143 c
11.1 ... 13 10 8575211430

B C A - - Centering propshaft in longitudinal direction.

- Push propshaft back as far as the stop with the

- - Slacken securing sc~ew (arrow D) for angle bracket fitting device.
o_t oil pressure pipes (feed and return, at rear).
- Mark position of centre bearing at body (arrow A) .
- Unscrew securing screw at oil pump cover (arrow
B) for angle bracket of oil pressure pipe (return, at - Push propshaft toward with the fitting device.
rear).
- Mark position of centre bearing on body (arrow B).
- Unscrew banjo bolt (arrow A) at closing cover for
oil pressure pipe (return, at rear) and seal hole
with plug.

- Unscrew banjo bolt at oil pump cover (arrow C) for

oil pressure pipe (feed, ·at rear) and seal hole with
plug.

..
34-8 39-20
 ....,. - Centre propshaft; the centre bearing must be
• B C A positioned between the markings {arrow C). ...... - Attach supporting device V.A.G 10-222A into the

~
left engine suspension and take up weight of
- Tighten centre bearing and calcµlated size of engine with the spindle.
• shims to body. ·

- Take off fitting device.

- Screw on heat shield below the propshaft.

- Install exhaust system.

Note:

Align exhaust system free of tension => Repair Group

26 - 8-Cyl. Fuel Injection Engine, Mechanics.

- Install front crossmember below exhaust system.

Tightening torques:
....,. - Remove noise insulation panel {arrows).
Centre bearing for propshaft to body ........... 20 Nm
Catalytic converter to front exhaust pipe ..... 25 Nm
Catalytic converter to suspension strap ...... 25 Nm
Front crossmember to body ........................ 1O Nm

. ..

39-21
34-5

Replacing seal for flang·e/ ...... - Unscrew crossmember {arrow) from body.
propshaft at rear final drive
{Final drive installed)

123456 7 8 9 Note:

Oil seal can only be replaced with final drive

lowered.

Sequence of operations ~ page 39-24

1 - Rear final drive

2 - 0-ring
• Always replace

3 - Sleeve
...... - Unscrew lambda probe {arrow 1) and thermo-
4 - Small clrclip sensor {arrow 2).

- Carefully bend up retaining clip {on left and right

of. gearbox housing) for cables of lambda probe
and thermosensor and take out electric wiring.

139-1847 I 39-22 34-6

 - Unscrew left and right distributor caps (wiring 5 - Cover with grooved ball bearing and
. remains connected). large circlip
....,. - Secure both distributor caps to breather hose of 6 - Countersunk-head screw, 25 Nm
crankcase with cable straps. (2 off)
1234 5 6 7 8 9 7 - Seal

8 - Plastic washer

9 - Flanged shaft
• Pay attention to position relative to
propshaft, mark if necessary
• Replace gasket between flanged
shaft and propshaft (take off protec-
tive sheeting and stick gask~t onto
flanged shaft) .

....,. - Unscrew top engine/gearbox connection bolts

(arrows).

34-3 39-23

..... - Unscrew air guide ring for viscous fan (arrows).

Sequence of operations
- Pull air guide ring up so that it jumps out of the
bottom of the guide. Removal

- Place air guide ring on fan wheel. ....,. - Separate exhaust system at double pipe clip.

' - Detach main and tail silencers from retaining

loops.

..... - Unscrew securing bolts for engine mount/right

top support at body (arrows).
....,. - Unscrew heat shield at separation point of ex-
haust system (arrows); only slacken both front
nuts (left in figure).

34-4
39-24
 Removing and installing gearbox
• - - Remove heat insulation plate behind cross-
I member I (arrows).
=
l
Removal
• Note:

Pay attention to radio coding (determine radio code

by asking customer before disconnecting battery).

- Disconnect earth strap from battery (below rear

seat).
- Take off front wheels.
- - Remove stabilizer bar (arrows).
- Unscrew bracket for left and right air guide pipe
(arrow).

- - Remove heat insulation plate in front of cross- - - Unscrew top part of air cleaner housing (4 screws
member I (arrows). on housing, 3 screws at rear of housing).

..

34-1
39-25

- - Unscrew bottom part of air cleaner housing (ar-

- - Remove cover of fuel tank (arrows) . rows), push back and then lift out and up. ·

- Place oil-drip tray below and drain oil in final drive. Note:

Nuts are self-locking - always replace.

'

- - Remove securing plate of ignition cable holder

- - If no marking points are provided, mark position of (arrows).
flange (arrow A) relative to rear final drive (arrow
B) in colour. Note:

Securing screws are self-locking - _

always replace.

34-2
39-26
 Fig. 3 Checking spring connection between
pressure plate and cover for cracking, ....,. - Remove closing part (arrows).
checking rivet fasteners are tight

....,. Clutches with damaged or loose riveted joints (ar-

rows) should be replaced.

....,. - Remove securing screws of propshaft at rear final

drive.

- Tie up propshaft.

Important!

Tie up propshaft only sufficiently as is nec-

essary to remove the output flange (universal
joint of propshaft may be damaged).

30-21
39-27

...... - Remove holder for handbrake cables (arrows).

- Slacken adjusting nut for handbrake cables and

detach cables at the compensating bar
=> Repair Group 46 - Running Gear.

...... - Slacken clip for fuel filter and move filter in direc-
tion of arrow (as far as fuel feed pipe permits) .

..

39-28
• 3 - Pressure plate
..... - Remove bracket for metering pump (only on • Removing and installing ~ Fig. 1
I
: vehicles fitted with auxiliary heater). • Checking ends of diaphragm spring
I
• - Support final drive with gearbox jack V.A.G 1383 1 2 3 4 ~Fi g.2

A and V.A.G 1359/2.

Important!
- Attach final drive with strap.
Pressure plates are protected against
- Carefully pull handbrake cables through eyes of corrosion and greased. They may only
crossmember II to the rear. be cleaned at the contact surface oth-
erwise the life of the clutch will be.
considerably reduced.

Before replacing the pressure plate,

pay attention to Fault Finding No. 9 -
faults at clutch and clutch mechanism.

4 - Screw, 25 Nm

..... - Slacken bolt (arrow A) for crossmember I.

- Unscrew bolt (arrow B) for crossmember I and

carefully lower final drive with gearbox jack.

30-1 9
39-29

..... Fig. 1 Removing and Installing clutch

..... - Unscrew crossmember II from crossmember I
(arrows). - Slacken and tighten screws in stages diagonally,
25Nm.
- Tie up ~rossmember I. • Change over counter-holder 10-201 when re
moving.
• The clutch plate is centred with the guide ·drift
3176. .

Important!

pressure plate must be resting properly on

flywheel all round. Do not Insert securing
screws unless this is the case..On no account,
counter-pull on pressure plate otherwise the
centering holes of the pressure plate and the
centering pins ofthe flywheel wlll be damaged.

..... Fig. 2 Checking ends of diaphragm spring

..... - Unscrew crossmember II from final drive (arrows)
and pull off beyond the flange of the final drive. Wear is permissible up to half the diaphragm spring
thickness. ·

Important! ·

When performing repairs, always match clutch

pressure plate and driven plate on the basis of
the chassis number according to the parts
catalogue.

30-20
39-30
 Servicing clutch - - Unscrew cover of final drive and pull out.

Note: A - Headles·s set screw M8/M10

1 2 3 4 For performing work on the clutch, remove
gearbox==? page 34-1.

1 - Flywheel
• Removing and installing
~ Workshop Manual
Audi 100 1991 ~
Repair Group 13-5-Cyl. Fuel Injec-
tion Engine (4-Valve)
• Removing and inserting needle
bearing in flywheel
' ~ Workshop Manual
Audi 100 1991~
Repair Group 13-5-Cyl. Fuel Injec-
tion Engine (4-Valve)

Notes: - - Press off sleeve.

VW 408a
• Ensure the centering pins are tightly - Take off small circlip.
seated.
• Contact surface for clutch lining must be
free of scoring, oil and grease.

30-17 39-31

2 - Clutch plate
• Centering ~ Fig. 1 - - Press out flanged shaft.
• Pay attention to installation position,
1 2 3 4 spring cage faces pressure plate
• Do not grease

Note:

Clean splines of input shflft and, if clutch

plates used, splines of hub. Remove corro-
sion and apply only a verjt thin film ofgrease·
G 000 100 to the splines of the input shaft.
After this, move clutch plate back and for-
ward on the input shaft until the hub moves
freely on the shaft.
Always remove excess grease.

• Diameter of clutch plate

~ Technical Data, page OQ-4

- - Remove seal with VW 681 .

Important!
- Thoroughly clean seat of seal.
Before replacing clutch plate, pay at-
tention to Fault Finding No. 9- faults at
clutch and clutch mechanism.
..

30-18
39-32
 Installation - Fig. 1 Adjusting clevis

- - Fit new seal -8- with a washer -A-, Size "a" = 109.5 ± 0.5 mm
Part No. 016 311 391 B (thickness 1.7 mm), onto
insertion drift 2005. - Turn clevis accordingly for adjusting.

Notes: Note:

• Thoroughly clean seat of seal. When measuring, the clevis must be at right angles
• Lightly oil outer diameter of seal. to the contact surface of the clutch master cylinder.
• Pack space between the sealing lips with univer-
sal grease.
• Open side of seal faces final drive. Important!

If the clutch pedal does not return by itself with

the clevis correctly adjusted, this may be
caused by:
• Air in the hydraulic system.
• The pedal in its mounting or the.over-centre
- - Insert seal as far as the stop. spring being stiff.
• The over-centre spring being fitted on
2005 - Take off insertion drift and washer-A-=> top Fig. wrongly.

39--33 30- 15

- - Press in flanged shaft (with plastic washer => Removing and installing over-centre
page 39--23, item 8). spring
- Fit on small circlip.
- Fit on sleeve and drive on with a plastic hammer. Note:
- Insert cover (with new 0-ring) and flanged shaft
into rear axle housing and screw tight. Remove the following parts before removing and
- Screw crossmember II onto final drive. installing the over-centre springs:
- Screw crossmember I onto crossmember II and • Left stowage compartment
body. => Repair Group 70, General Body Repairs.
- Attach bracket with metering pump (only for ve- • Left legroom air vent
hicles with auxiliary heater}. => Repair Group 80, General Body Repairs.
- Push back fuel filter and tighten clip.
- Attach handbrake cables to compensating bar. - Use the assembly clip 3246 for removing and in-
- Attach bracket with handbrake cables. stalling the over-centre springs:
32-109 - Adjust handbrake - Push assembly clip sideways over the over-centre
=> Repair Group 46 - Running Gear. spring.
- Bolt on propshaft, ensuring that the marking points - Depress clutch pedal and remove over-centre
on the flanges of the propshaft and of the rear final spring together with assembly clip.
drive are aligned => page 39--26, Fig. 39-1840. - Installation is perfo.rmed in the reverse order.
- Adjust propshaft => page 39-18.
- Screw on closing part (support for exhaust system).
- Install cover of fuel tank. Important!

3246 When installing, pay attention to coloured

marking of over-centre springs => page 30-13
and30-14.

Notes:

• The assembly clip has been shown with the pedal

bracket removed to simplify the illustration.
• Before assembling, grease the bearing journals
with white solid lubricating paste.

39--34 30-16
 - Install heat insulation panels in front of and behind
14 - Master cylinder crossmember II.
• Replace if leaking
- Install heat shield and separation point of exhaust
• Adjusting clevis=> page 30-15 system.
5 6 - Install exhaust system (main and final silencers)
15 - Bolt, 20 Nm
• Always replace double pipe clip.
• Attach clevis to clutch pedal - Add gear oil
• Capacity and specification=> page 00-7.
16 - Clutch p~dal .
• Can be replaced with pedal bracket Notes:
installed
• Is fixed in position by adjusting the
• It is essential to clean any residues of locking fluid
clevis
from the tapped holes in the flanged shaft for the
• Fit onto the shaft of the pedal bracket
propshaft of the rear final drive before installing
• I~ supplied as service part with injec-
the propshaft. The tapped holes can be cleaned
tion-moulded bearing bush. Bearing
with a thread tap.
bush cannot be replaced
• A lways fit new self-locking nuts and bolts.
17 - Locking element • Align exhaust system free of tension => Repair
~roup 26 - 8-Cyl. Fuel Injection Engine, Mechan-
• Always replace
• Fit onto the shaft of the pedal bracket
ics.

18·- Over-centre spring

• Marked in yellow
• Grease at the bearing points of the
bearing journals with white lubricat-
16 ing paste before assembling
10 • Removing and installing
=> page 30-16
15 _ __ __ _...:_,,
1 4 - - - - - --

13 12 11
130-428 I .. 39-35 ·
30-13

19 - Locking element Tightening torques:

• Always replace
• Fit onto the bearing journal Cover. to rear final drive ............................... 25 Nm
1 3 4 ·s 6 Crossmember II to rear final drive ............... 45 Nm
Crossmember I to crossmember II ......... .... .45 Nm
Note:
Crossmember I to body .. .......... .. ................. 45 Nm
Does not need to be removed in order to take Bracket for metering pump to body ............. 25 Nm
out the over-centre spring. Clip for fuel filter to body .............................. 1O Nm
Propshaft to rear final drive ......................... 55 Nm
20 - Locking element Closing part to crossmember I .................... 55 Nm
• Always replace Cover of fuel tank to body ... ................. .......20 Nm
• Fit onto pin Double pipe clip to exhaust system ............ .40 Nm

Note:

Does not need to be removed in order to take

out the over-centre spring.

21 - Over-centre spring
• Marked in white
• Grease at the bearing points of the
bearing journals with white lubricat-
ing paste before assembling
• Removing and installing
=> page 30-16
10

13 12 11
I3o-42a I 39-36
30-14
 Replacing oil seal for right flanged 7 - Locking element
shaft • Always replace
• Fit onto the shaft of the pedal bracket
(Final drive installed) 1 4 5 6
8 - Combination nut, 20 Nm
- - Remove cover of fuel tank (arrows).
9 - Brake light switch
• Always replace
• Press into the fitted clip
• Adjust with clevis attached:
- Operate brake pedal
- Press in brake light switch as far
as the stop
- Pull back brake pedal as far as the
stop by hand

Note:

Adjusting clevis for brake pedal => Repair

Group 46, Running Gear.

- - Detach handbrake cable at right brake caliper

(arrows).

Note: 10
When detaching the handbrake cable, ensur~ that
the plastic sheathing of the handbrake cable is not 15 - -- - - - --'
damaged.
14 ------~~

13 12 11
I30-42a I
.. 39-37 30-11

- - Push handbrake cable out of fixture (arrow A). 10 - Air admission valves for cruise
control system
- Unscrew trapezium arm from crossmember (ar- • Always .replace
row B) and carefully lower with gearbox jack 1 4 5 6 • Press into the fitted clip
V.A.G 1383 A and vehicle jack support. • Adjust with clevis attached:
- Operate brake or clutch pedal
- Unscrew drive shaft and place down (arrow C). - Press in air admission valves as
far as the stop
- Unscrew flanged shaft; secure with drift when - Pull back brake or clutch pedal as
performing this step to prevent it turning. · far as the stop by hand
- Place oil drip tray below. 11 - Clips for air admission valves of
cruise control system and for brake
- Pull out flanged shaft by hand; detach with two, light switch
;:issembly bars, if necessary. • Press into holes provided in pedal
bracket as far as the stop using
pliers
Important!
12..:.. Lock nut, 10 Nm
When levering off flanged shaft, do not dam- • lighten after adjusting clevis
age shoulder on axle housing.
13 - Screw, 20 Nm .
- Leverout oil seal with a suitable tool, e.g. assembly • Screw master cylinder onto pedal
bar. bracket
- Clean seat for seal.
10

13 12 11
39-38 30-12
 List of operations - - Insert seal for flanged shaft as far as the stop
using 2062.
1 2 4 5 6 7 Pedal cluster
(Vehicles with 4.2 litre engine) Notes:

) Note:

Grease all bearing points with white solid

• Lightly oil outer diameter of seal.
• Pack space between the sealing lips with univer-
sal grease.
lubricating paste, PartNo.AOS 126000 005, • Open side of seal faces final drive.
before installing.
- Secure flanged shaft with hex. socket screw.
Important! - Replace gasket between drive shaft and flanged
shaft (pull off protective sheet and stick gasket
The travel of the brake pedal must not onto the joint).
be shortened by additional floor cov- - Install drive shaft.
erings. - Bolt trapezium arm to crossmember.
- Attach handbrake cable to brake caliper and
1 - Cable clip press into fixture.
• Hold ·the feed hose to the pedal - Install cover of fuel tank.
bracket - Check oil level in final drive, correct if necessary.
• Capacity and specification==? page 00-7.

10

13 12 11 .
130-4281
30-9
39-39

2 - Feed hose Tlghtenlng torques:

• Lay at pedal bracket accordingly and
secure with cable clip Hex. socket screw of flanged shaft ............~ .10 Nm
1 2 4 5 6 and torque a further 90°
Important! Drive shaft to flanged shaft .......................... 80 Nm
Trapezium arm to crossmember .................. 85 Nm
Feed hose for master cylinder must not • Always fit new self-locking nut
touch over-centre spring. Cover plate of fuel tank to body ................... 20 Nm

3 - Self-locking nut, 20 Nm
• Always replace

4 - Pedal bracket

5 ..:. Return spring for brake pedal

• Attach with the long leg t9 the pedal

I19}) bracket and with the short leg to the

brake pedal

6 - Brake pedal
• Fitontotheshaftofthepedal bracket
18 . • Is supplied as service part with injec-
tion-moulded bearing bush . Bearing
17 bush cannot be replaced
16
10

15
14

13 12 11
130-428 1
30-10 39-40
 Replacing oil seal for left flanged shaft - Fig. 1 Adjusting clevis

(Final drive installed) Size "a" = 109.5 ± 0.5 mm

- - Separate exhaust system at double pipe clip. - Turn clevis accordingly for adjusting.

- Detach main and final silencers from retaining Note:

loops.
When measuring, the clevis must be at right angles
to the contact surface of the clutch master cylinder.

Important!

If the clutch pedal does not return by itself with

the clevis correctly adjusted, this may be
caused by:
• Air in the hydraulic system.
• The pedal in its mounting or the over-centre
spring being stiff.

- - Remove cover plate for drive shaft (arrows).

39-41 30-7

- - Detach handbrake cable at left brake caliper Removing and installing over.:centre
(arrows). spring
Note:
Note:
When detaching the handbrake cable, ensure that
the plastic sheathing of the handbrake cable is not Remove the following parts before removing and
installing the over-centre spring:
damaged.
• Left stowage compartment
=> Repair Group 70, General Body Repairs.
• Left legroom air vent
=> Repair Group 80, General Body Repairs.

- Use the assembly clip 3246 for removing and in-

stalling the over-centre sprrng:
- Push assembly clip sideways over the over-cen-
- - Detach spring for brake pressure regulator (ar- tre spring.
row) (only on vehicles without self-levelling sus- - Depress clutch pedal and remove over-centre
pension). spring together with assembly clip.
- Installation is performed in the reverse order.

Notes:

• The assembly clip has been shown with the pedal

bracket removed to simplify the illustration.
• Before assembling, grease the· bearing journals
with white solid lubricating paste.

39-42 30-8
 14 - Master cylinder - - Unscrew trapezium arm from crossmember (ar-
• Replace if leaking row A) and lower with gearbox jack V.A.G 1383A
• Adjusting clevis=> page 30-7 and small vehicle jack support.
1 4 5 6 7 - Press handbrake cable out of the fixture (arrow B).
15 - Pin
• Attach clevis to clutch pedal I

- Unscrew drive shaft (arrow C).

16 - Clutch pedal
• Can be replaced with pedal bracket - Place oil drip tray below.
. installed
• Is fixed in position by adjusting the
clevis
• Fit onto the shaft of the pedal bracket
• Is supplied as service part with injec-
tion-moulded bearing bush. Bearing
bush cannot be .replaced

17 - Locking element
• Always replace
• Fit onto the shaft of the pedal bracket - - Unscrew flanged shaft.

18 - Pull out flanged shaft at the screwed-in screws.

17 Note:
16-~ Do not lose shim between flanged shaft and differ-
ential.

13 20 14 12 15 11
I30-427 I 39-43
30-5

18 - Over-centre spring - - Lever out seal with assembly bar.

1 4 5 6 7
• Grease at the bearing points of the
bearing journals with white lubricat-
ing paste before assembling
• Removing and installing
=>page 30-8
/ - Thoroughly clean seat of seal.

19 - Locking element
• Always replace
• Fit onto the bearing journal

Note:

Does not need to be removed in order to take

out the over-centre spring.

20 - Locking element
• Always replace
• Fit onto pin
- - Screw threaded rod - A- from assembly device
3066 into the differential.

Notes:
17
• Lightly oil outer diameter of seal.
16 • Pack space between the sealing lips with univer-
sal grease.
• Open side of seal faces final drive.

- Fit seal onto the thrust plate 3066/1 and pull in as

far as the stop with the hex. nut from 306611 .

13 20 14 12 15 11
130-427 I 39-44
30-6
- Secure flanged shaft with hex. socket screw.
7 - Locking element
Note: • Always replace
• Fit onto the shaft of the pedal bracket
Before installing the flanged shaft, insert shims. 1 4 5 6 7
8 - Combination nut, 20 Nm
- Replace gasket between drive shaft and ·flanged
shaft (pull off protective sheet and stick gasket 9 - Brake light switch
onto the joint) . • Always replace
• Press into the fitted clip
- Install drive shaft. • Adjust with clevis attached:
- Operate brake pedal
- Bolt trapezium arm onto crossmember. -: Press in brake light switch as far
as the stop
- Attach spring for brake pressure regulator (only - Pull back brake pedal as far as the
on vehicles without self-levelling suspensiQn). stop by hand

Note:
Note:

Checking and adjusting brake pressure regulator Adjusting clevis for brake pedai => Repair
=> Repair Group 47.:.. Running Gear. . Group·46, Running Gear.

- .Attach handbrake cable to brake caliper. 18

- Press handbrake cable into fixture. 17
~ Install cover plate for drive shaft. 16 -~

13 20 14 12 15 11
39-45 I30-427 I
30-3

- Install exhaust system (main and final silencers). 10 - Air admission valves for cruise
control system
Notes: • Always replace
1 5 6 7 • Press into the fitted clip
• Always fit new double pipe clip. • Adjust with clevis attached:
• Align exhaust system free of tension => Repair .- Operate brake or clutch pedal
Group 26 - 8-Cyl. Fuel Injection Engine, Me- - Press in air admission valves as
chanics. far as the stop
- Pull back brake or clutch pedal as
- Check oil level in final drive, correct if necessary. far as the stop by hand
• Capacity and s p ecificati on ~ page 00-7.
11 - Clips for air ~dmisslon valves of
Tightening torques: cruise control system and for brake
light switch
Hex. socket screw of flanged shaft ... ........... 1o Nm • Press into holes provided in pedal
· and torque a further 90° b~acket as far as the stop using
Drive shaft to flanged shaft .......................... 80 Nm phers.
Trapezium arm to crossmember ..................85 Nm
• Always fit new self-locking nut · 12 - Lock nut, 10 Nm
Cover plate for drive shaft ........................... 25 Nm • Tighten after adjusting clevis
Double pipe clip to exhaust system ........ .....40 Nm
• Always replace · 13 - Screw, 20 Nm
~ Screw master cylinder onto pedal
bracket
17
16 --/'

13 20 14 12 15 11
39-46
l30-427 I 30-4
 Servicing clutch mechanism
Removing and installing rear final drive
List of operations Removal
1 4 5 6 7
Pedal cluster - Take off rear wheels.
(Vehicles with 3'.6 litre engine)
...... - Separate exhaust system at double pipe clip.
Note:
- Detach main and final silencers from retaining ,
Grease all bearing points with white solid loops.
lubricating paste, PartNo.AOS 126000 005,
before installing.

Important!

The travel of the brake pedal must not

be shortened by additional floor cover-
ings.

1 - Cable clip
• Hold the feed hose to the pedal
bracket
17 ...... - Unscrew heat shield at the separation point of the
exhaust system (arrows), only slacken both front
16 nuts {left in figure).

13 20 14 12 15 11
l 30-427 I 30-1
39-47

2 - Feed hose
• Lay at pedal bracket accordingly
and secure with cable clip ...... - Remove cover plate of fuel tank (arrows).

1 4 5 6. 7 Important/

Feed hose for master cylinder must not

touch over-centre spring.

3 - Self-locking nut, 20 Nm
• Always replace

4 - Pedal bracket

5 - Return spring for brake pedal

• Attach with the long leg to the pedal
bracket and with the short leg to the
brake pedal

19 6 - Brake pedal
• Fit onto the shaft of the pedal bracket ...... - Remove- heat. insulation plate behind cross-
18 • Is supplied as service part with in- member I (arrows).
jection-m ou Ided bearing bush.
17 Bearing bush cannot be replaced

16

13 20 14 12 15 11
I30-427 I
30-2
39-48
 Synchronizer rings
- - Remove heat insulation plate in front of cross-
• Do not mix up.
member I (arrows).
When re-using, allocate again to the same gear-
wheel.
• Check for signs of wear, replace if necessary.
• Lubricate with gear oil before inserting. ·

Clutch mechanism
Take out clutch slave cylinder without separating the
piping system when removing the gearbox. Do not
operate clutch pedal any more after removing the
. slave cylinder otherwise the piston will be pressed
out of the slave cylinder and rendered unusable.

- - Slacken securing screws of propshaft at rear final

drive after marking position of flange -A- relative ·
to rear final drive-B-in colour if no marking points
are provided.

- Unscrew propshaft and tie up.

Important!

Tie up propshaft only as much as is necessary

to remove the final drive.

00-15
39-49

- - Remove closing part (arrows). Gears, synchronizer bodies, inner

races for selector gears
• When installing, press in as far as the stop with
zero axial play.
• Heat gears to approx. 120°C befqre pressing on.
• Heat inner rings for selector gears to approx.
80°C before pressing on·.

Selector gears

After installing
• 1st to 4th speed selector gears
check for axial play of 0.15 to 0.35 mm .
• 5th and 6th speed selector gears
check that they move freely when rotated.

- - Unscrew cover plate for left drive shaft (arrows).

00-16
39-50
Note: - - Unscrew left bracket of handbrake cable from
final drive (arrows).
Tensioning sleeve or roll pin for attaching 5th/6th
speed selector fork/selector rail must only be re-
moved and inserted with the special tool.

Nuts, bolts

• Slacken and tighten nuts and bolts for securing

covers and housings diagonally.
- Do not twist particularly sensitive parts -e.g.
clutch pressure plates-and slacken and tighten
in stages diagonally.
• Tightening torques are indicated for non-oiled
nuts and bolts.
• Always fit new self-locking nuts and bolts.
- - Detach spring for brake pressure regulator (ar-
Note: row) (only on vehicles without self-levelling sus-
pension).
Clean any residues of microencapsulation from
tapped holes into which self-locking bolts or bolts
inserted with sealant are screwed in. If not, there is
a risk of the bolts seizing when screwed in and
shearing off when removed again. The tapped holes
can be cleaned with a thread tap.

00-13
39-51

Bearings
• Place needle bearings in position with the in-
- - Detach handbrake cable at left brake caliper
scribed side (thicker metal) facing the insertion (arrows).
drift.
• Grease needle bearings for the input shaft in the Note:
crankshaft.
• Oil all bearings in the gearbox with gear oil before
When detaching the handbrake cable, ensure that
inserting. Oil particularly carefully for measuring
the plastic sheathing of the handbrake cable is not
friction torque. damaged.
• Heat inner races of taper roller bearings to approx.
100°C for installing; when fitting , press in as far as
the stop with zero axial play.
• Do not mix up outer and inner races of equal sized
bearings. Bearings are matched.
• Replace all taper roller bearings which are fitted to
the same shaft and use the same makes.

Shims
• Measure shims at several points with a microm-
eter. Different tolerances enable the required
shim thickness to be precisely gauged.
• Check for burrs or signs of damage. - - Unscrew left trapezium arm from crossmember
• Install only shims which are in perfect condition. (arrow A) and lower with gearbox jack V.A.G 1383A
and small vehicle jack support.

- Press handbrake cable out of the fixture (arrow B) .

- Unscrew drive shaft and place down (arrow C).

00-14
39-52
~ - Unscrew right-hand bracket of handbrake cable General repair instructions
from final drive (arrows).
The maximum possible care and proper tools are
essential requirements for performing proper and
successful gearbox repairs. The generally applica-
ble basic rules of safety naturally also apply to repair
work.

A number of generally applicable notes for individual

repair operations are summarized here. They apply
to this Workshop Manual.

Gearbox

• When replacing the gearbox or final drive, fill with

gear oil.
Capacity and specification~ page OQ-4 and 00-7.

• When installing gearbox, ensure the dowel sleeves

are correctly seated .
.....,. - Detach handbrake cable at right brake caliper
(arrows). . Gaskets, seals
• Thoroughly clean mating surfaces beforehand.
Note: • Replace paper gaskets.
• Replace 0-rings.
When detaching the handbrake cable, ensure that
the plastic sheathing of the handbrake cable is not
damaged.

00-11
3~53

• .Radial shaft seals

....... - Press handbrake cable out of fixture (arrow A).
Before installing:
- Unscrew right trapezium arm from crossmember - Lightly oil outer diameter.
(arrow B) and carefully lower with gearbox jack - Pack the space between the sealing lips with
V.A.G 1383A and small vehicle jack support. grease.
- Unscrew drive shaft and place down (arrow C). After installing:
- Check oil level; top up any oil loss. Capacity and
specification~ page 00-4 and 00-7.

Sealant
• Thoroughly clean mating surf(lces and apply
sealant AMV 188 200 03.
• Apply an even coat -not too thick- of sealant.
- Keep vent holes clear.

Locking elements
• Replace circlips.
• Do not over-tension circlips.
.....,. - Unscrew handbrake cables at body (arrows). • Circlips must be properly seated in the base of the
groove .

.....,. • .Replace tensioning sleeves.

Installation position: Slot longitudinal to flow pat-
tern.

• Roll pins· (used from 01 /92 in place of tensioning

sleeves)
Installation position: indpendent of force pattern.

00-1 2
3~54
 ._ - Unscrew bracket for metering pump {only on
Calculation of transmission ratio vehicles with auxiliary heater).
Example:

6th gear Final drive

Driving gear ZG 1 = 41 ZA1 = 8

Driven gear ZG2 = 23 ZA2 = 31

Z2 No. of teeth driven gear

i = -- =- - - - - - - - -
z1 No. of teeth driving gear

z~ 23
.ia = Gear ratio = - = - =0.561 ._ .- Slacken clip for fuel filter and move filter in direc-
ZG, 41 tion of arrow (as far as the fuel fee<;i pipe permits).
ZA2 · 31
iA = Axle ratio =- = - =3.875
ZA1 8

i101• = Total ratio = ia x iA

23 31
= - x - =2.134
41 8

00-9 3~55

Notes regarding output test, brake test ._ - Rear suspension: .

and towing vehicle Unscrew nut - A-.

~ Special Information Bulletin " PowerTransmission" - Support final drive with gearbox jack V.A.G 1383A
No.8. and V.A.G 1359/2.

- Secure final drive with strap.

- Pull handbrake cables carefully forward through

the eyes of the crossmember II.

._ - Slacken bolt (arrow A) for crossmember I.

- Unscrew bolt {arrow B) for crossmember I and

carefully lower crossmember I with gearbox jack.

00-10 3~56
~ - Unscrew crossmember II from crossmember I Code letters, allocation, ratios, capacities
(arrows).

- Tie up crossmember I. Rear final drive

Code letters AXZ

-
Manufactured from 01.90
to

Allocation Type/Model Audi VB 1991 ...

3.61-184 kW
Engine: 8-cylinder 3.61-184 kW*)
Vengine 4.2 1-206 kW

Ratios Final drive 37:9=4.111

Z2: Z1 = i
~ - Unscrew crossmember II from final drive (arrows)
and guide away beyond the flange of the final Capacity 1:7 1
drive.
Specification Gear oil GL 5 SAE 90
- Slowly lower final drive complete at front with rear (MIL-L 21058)
gearbox support.
Drive shaft flange dia. 108 mm
Note:
Allocation Manual gearbox CBM
When lowering the final drive, at the same time pull (code letters) CBN
away to the left from the fuel tank.
Remarks *) Switzerland

- Lift final drive out of rear axle beam with gearbox

support and securing bolt.

39-57 00-7

Installation Power transmission diagram

Installation is performed in the reverse order. Pay Designation

attention to the following points:
1 2 3 A2 1 - Engine
Notes: 2 - Clutch
3 - Gearbox
0
• It is important to clean any residues of locking fluid 4 - Input shaft (main shaft) .
from the tapped holes in the flanged shaft for the 5 - Front differential
propshaft of the rear final drive before installing 6 - Front drive pinion (output shaft)
the propshaft. The holes can be cleaned with a 7 - Hollow shaft
thread tap. 8 - Torsen differential
• Always fit new self-locking nuts. 9 - Propshaft
• Always replace gaskets between flanged and 1O - Rear drive pinion
drive shafts as well as the propshaft and rear final 11 - Torsen differential - rear final drive
drive => page 39-11, item 4 (pull off protective
sheet and stick gasket into flanged shaft). Ratios
~. When installing the propshaft, ensure that the
marking points of the flange of the propshaft I - 1st gear
(arrow A) and of the flanged shaft of the rear final II - 2nd gear
drive (arrow 8) are aligned. Ill- 3rd gear
• After installing, adjust propshaft => page 39-18. IV- 4th gear
• Always replace double pipe clip when installing V - 5th gear
exhaust system. 4 7 8 9 10 11 VI- 6th gear
R - Reverse

• •
Align exhaust system free of tension
=> Repair Group 26-8-Cyl. Fuel Injection Engine, A1 - Front final drive
Mechanics. A 2 - Rear final drive
• Check oil level in final drive, add oil if necessary. • T - Speedometer drive (electronic)
- Capacity and specification => page 00-7. Arrows -face in direction of travel

135 - 1362 1
39- 58 00-8
 Final drive identification Tightening torques:

- The final drive 017 is also allocated to the manual Crossmember II to final drive ......................45 Nm
gearbox 01E4 WD. Crossmember II to crossmember I .............. 45 Nm
Crossmember I to body ............................... 45 Nm
Allocation=> Technical Data, page 00-7 Rear suspension to crossmember ............... 50 Nm
Bracket for metering pump to body ............. 25 Nm
Clip for fuel filter to body .... .......................... 10 Nm
Drive shaft to rear final drive ......... .............. 80 Nm
Trapezium arm to crossmember .................. 85 Nm
Bracket for right handbrake cable to final
drive ............................................................. 25 Nm
Bracket for left handbrake cable to final
drive ........................ ..................................... 25 Nm
Cover plate for drive shaft to fi nal drive ...... . 25 Nm
Closing part to crossmember I .................... 55 Nm
Propshaft to rear final drive ......................... 55 Nm
Cover plate of fuel tank to body ................... 20 Nm
Double pipe clip to exhaust system .......... .. .40 Nm
Tightening torque of wheels ............... ........ 110 Nm

- Code letters and date of manufacture of rear final

drive - up to 02.92 (arrow 1).

Example: AXZ 13 08 1

I I I
Code letters Day Month Year
I
(1991)
of manufacture
..

00-5 39-59

- Code letters and date of manufacture of rear final

drive - from 02.92 (arrow 2).

Example: AXZ 08 03 2

I I
Cocje letters Day
I
Month
I
Year
(1992)
of manufacture

OCH>
 Gearb9x identification ·
The 6-speed manual gearbox 01E4 WO is installed
in the Audi VB from 07.91 in combination with the
3.6 litre and 4.2 litre 8-cylinderfuel injection engines.

..... Location on gearbox

Code letters and serial No. (arrow 1)

Manual gearbox 01 E (arrow 2)

00-1

..... Code letters and serial number of ge_arbox (arrow 1).

Example: CBN 00041

I
Code
I
Serial number
letters of gearbox

Note:

~ The code letters of the gearbox are also listed in the

. vehicle ·data plates.

..... Manual gearbox 01 E (arrow 2):

00-2
 Contents

00 Technical data Page

Gearbox identification 00- 1

- Code letters, allocation, ratios, capacities 00- 3
Final drive identification 00- 5
- Code letters, allocation, ratios, capacities 00- 7
Power flow diagram 00- 8
Calculation of transmission rati 00- 9
Notes regarding output test, brake test and towing vehicle 00-10
General repair instructions 00-11

30 Clutch Page

Servicing clutch mechanism 30- 1

- List of operations for pedal cluster (3.6 litre engine) 30- 1
- Removing and installing over-centre spring 30- 8
- List of operations for pedal cluster (4.2 litre engine) 30- 9
- Removing and installing over-centre spring 30-16
- List of operations for hydraulics *)
- Bleeding clutch system *)
Servicing clutch release mechanism *)
Servicing clutch 30-17

34 Controls, Housing Page

Servicing selector mechanism *)

Adjusting and checking selector mechanism *)
Removing and installing gearbox 34- 1
- Removal 34- 1
- Installation 34- 13
Removing and installing oil pump 34-17
- Removal 34-17
- Installation 34-20

39 Final drive, Differential Page

Replacing flanged shaft seal 39- 1

Replacing electronic speedometer sender and gear 39- 2
Replacing flange/propshaft seal at gearbox 39- 4
- Sequence of operations 39- 6
Removing and installing propshaft 39-10
- Sequence of operations 39- 13
- Adjusting 39-18
Replacing flange/propshaft seal_at rear final drive 39-22
- Sequence of operations 39-24
Replacing oil seal for right flanged shaft 39-37
Replacing oil seal for left flanged shaft 39-41
Removing and installing rear final drive 39-47
- Removal 39-47
- Installation 39- 58

*) Not described in this booklet

=> Workshop Manual Audi 100 1991
Booklet 5- and 6-Speed Manual Gearbox 01 E Edition 01 .92
 Code letters, allocation, ratios, capacities

Manual gearbox 6-speed 01 E 4 WO

Code letters CBM CBN

Manufactured from 07.91 07.91

to

Allocation Type/Model Audi V8 1991 ...

Engine: 8-cylinder 3.61-184 kW 3.6 I - 184 kW *)

V engine 4.21-206 kW

Ratios Final drive 37: 9 = 4.111 37: 9=4.111

Z2: Z1 = i Gearbox 1st gear 28: 8 = 3.500 28: 8 = 3.500

2nd gear 34:18 = 1.~89 34:18 = 1.889

3rd gear 33:25 = 1.320 32:26 = 1.231

4th gear 30:29 =1.034 29:30 = 0.967

5th gear 30:35 = 0,857 29:36 = 0.806

6th gear 27:37 = 0.730 26:38 = 0.684

Reverse 38:11 = 3.455 38:11 = 3.455

Speedometer electronic 8 pulses I wheel revolution

Remarks *) Switzerland

00-3

Code letters, allocation, ratios, capacities

Manual gearbox

Code letters CBM CBN

• Capacity 3.5 I *) + 0.1 I gear oil additive Part No. G 009 000 01

Specification Gear'oil G 50 (synthetic oil) SAE 75 W-90

Clutch mechanism hydraulic

Clutch plate dia. 240mm

Drive shaft flange dia. 108mm

Total ratio in top gear 3.000 2.813

Allocation Rear final drive AXZ

(code letters)

Remarks *) + 0.3 I for oil pipes and oil cooler

00-4