Audi 100/A6

1990-1997 of release

Repair and car operation

9.2.9. Evident repair of a transmission 012

THE GENERAL DATA

Transmission 012 in gathering

1. A conic roller bearing 2. A gear wheel of transfer of a backing 3. A gear wheel of 5th transfer 4. A gear wheel of 4th transfer 5. A gear wheel of 3 transfers 6. A gear wheel 2nd transfers 7. A gear wheel of 1st transfer

8. A conic roller bearing 9. Differential 10. Carter of coupling 11. The ball-bearing 12. Carter of a transmission 13. A leading shaft 14. The block of gear wheels of an intermediate shaft

Technical characteristics, 5-speed transmission 012

Code	AKL/AUF	ALP/AАD
	4-cylinder	5-cylinder
Transfer number:
– The main transfer	37:9 = 4.111	37:10 = 3.700
– The first transfer	39:11 = 3.545	39:11 = 3.545
– The second transfer	40:19 = 2.105	40:19 = 2.105
– The third transfer	39:30 = 1.300	39:30 = 1.300
– The fourth transfer	33:35 = 0.943	35:34 = 1.029
– The fifth transfer	30:38 = 0.789	31:37 = 0.838
– Backing transfer	35:10 = 3.500	35:10 = 3.500
Speedometer	The electronic
Greasing volume	2,35 litres
The specification	Transmissionnoe oil G 50 (synthetic)
SAE 75 W 90
Coupling drive	The hydraulic
Diameter of a disk муфты couplings	210 mm	228 mm
Diameter of a flange of a leading shaft	100 mm	108 mm
Speed on the highest transfer at 1000 rpm	34 km/h	36 km/h

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The prevention

Do not grease the lever mechanism of the lever of a gear change.

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THE LEVER MECHANISM OF THE LEVER OF THE GEAR CHANGE, ADJUSTMENT / CHECK

Transmission

Removal

PERFORMANCE ORDER

1. Disconnect a wire of the negative plug of the accumulator. 2. Turn off three top bolts of fastening of the engine and a transmission. 3. Disconnect a wire of grounding of a transmission from a check point. 4. Remove a socket of connection of a sending device of a speedometer and a socket of a multipurpose sending device having squeezed clips. 5. Disconnect a connection socket каталитического the converter. 6. Remove a protective plate картера transmissions. 7. Turn off bolts of fastening of a final collector. 8. Remove a forward exhaust pipe. 9. Remove a back cross-section beam. 10. Disconnect ropes of an automatic tension of seat belts from a transmission. 11. Remove draught of a gear change. 12. Remove a protective plate картера couplings. 13. Remove a protective plate of a leading shaft. 14. Disconnect semiaxes from a transmission. 15. Turn a steering wheel against the stop to the right and fix semiaxes having adhered them to a body. 16. Remove the working cylinder of coupling. 17. Remove an arm of the mechanism of a steering. 18. Establish the engine on a support. 19. Establish a transmission on a support 20. Remove fastening on a back left part of a transmission. 21. Remove forward fastening of the engine. 22. Remove the bottom bolts of fastening of a transmission and the engine. 23. Slowly lower a transmission.

Installation

Installation is made in sequence, return to removal.

At installation pay attention to the following:

     – Check up, that centering plugs have been established correctly.
     – Establish the working cylinder of coupling into place by means of the lever so that the bolt was inserted easily.

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The prevention

The bolt for fastening of the working cylinder of coupling has the pointed end for simplification of installation.

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The moments of an inhaling of carving connections

Transmission fastening to the engine:
– Bolts М8	25 Н.м.
– Bolts М10	45 Н.м.
– Bolts М12	65 Н.м.
Fastening of a leading shaft to a flange:
– М8	45 Н.м.
– М10	80 Н.м.

TRANSMISSION FASTENING TO THE ENGINE

The 4-cylinder engine

1 = bolt М12 x 70
2 = bolt М12 x 85
3 = bolt М12 x 100
4 = bolt М8 x 15

The 5-cylinder engine

1 = bolt М12 x 70
2 = bolt М12 x 80
3 = bolt М12 x 90
4 = bolt М12 x 100
5 = bolt М11 x 120
6 = bolt М10 x 50
7 = bolt М10 x 40
8 = bolt М8 x 40

Arrangement of centering plugs: points And and In


Arrangement of centering plugs: points And and In

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The prevention

If it is necessary for you to replace картер the main transfer or a conic roller bearing of a leading gear wheel or a hollow shaft and a deviation r it is not designated on a conic cogwheel, position of installation of a leading gear wheel should be defined before removal картера transmissions (it is necessary to spend measurements of the valid size of a deviation).

Before installation картера transmissions, check up, that directing plugs have been established in картере transmissions.

Address with a speedometer sending device very accurately. Do not drop it, differently speedometer indications can be not exact.

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The mechanism of the main transfer

1. A speedometer drive 2. Дифферкнциал 3. A sealing ring 4. A cover of the main transfer 5. A bolt with a head under a face key – 25 Н m. 6. A lock ring 7. A flange of a leading shaft 8. A bolt with a head under a face key – 35 Н m. 9. The directing plug with a sealing ring 10. A concave washer 11. A lock ring 12. The ball-bearing of a leading shaft 13. A lock ring 14. A speedometer sending device 15. Carter of the main transfer

16. A bolt with a head under a face key – 10 Н m. 17. A connection socket многофугкционального a sending device 18. A cover of the channel of the lever of a gear change 19. A multipurpose sending device 20. A locking film for a multipurpose sending device 21. A bolt 25 Н m. 22. The lock of 5th transfer and backing transfer 23. A lock ring

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The prevention

спидометра1 it is possible to replace a drive, without removing a transmission.

The differential 2 can be removed, without removing картер a transmission.

Remove a sealing ring 3 by means of tool VW 681.

Герметизируйте a cover of the main transfer 4 by means of hermetic AMV 188 200 03.

Always replace lock rings 6 and 23.

Establish a flange of a leading shaft by means of tool VW 295.

The party of a concave washer 10 with smaller diameter is turned to directing plug (the concave party).

Lock rings 11, 13 mark after removal.

Sealing ring of a flange of a leading shaft – remove by means of tool VW 681 and establish (on 5 mm below a surface картера the main transfer) by means of tool VW 195.

Carter of the main transfer 15: a sealing ring of a flange of a leading shaft – remove by means of tool VW 681. Establish (on 5 mm below a surface картера the main transfer) by means of tool VW 195. The plug of a rod of switching 3-ej/4th transfer – establish by means of tools VW 295 and VW 295А. Герметизируйте by means of hermetic AMV 188 200 03.

Cover of the channel of the lever of a gear change 18 – tighten a bolt of fastening to 20 Н.м.

22 it is possible to replace the lock of 5th transfer and transfer of a backing, without removing a transmission. The oblique party of the plastic plug is turned to a switching shaft. The moment of an inhaling of bolts of fastening: 10 Н m.

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The mechanism of a leading shaft

1. Internal draught of switching 2. A rod of switching of 1st, 2nd, 5th transfers and transfer of a backing with a switching plug 3. A leading gear wheel with hollow shaft 4. Carter of a transmission 5. A bolt with a head under a face key - 25 Н m. 6. A bolt with a head under a face key for an axis of transfer of a backing – 35 Н m. 7. A bolt with a head under a face key – 25 Н m. 8. The lock 9. A bolt with a head under a face key – 40 Н m. 10. A washer 11. A switching shaft

12. A washer 13. A bolt with a head under a face key 14. A switching rod 3-ej/4th transfers and a switching plug 15. A leading shaft 16. A lock ring 17. A washer 18. A gear wheel передачт a backing 19. The needle bearing of a conducted gear wheel of transfer заденго a course 20. A persistent washer

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The prevention

Remove a sealing ring of internal draught of switching 1 by means of tool VW 681 and establish заподлицо by means of tool VW 460/2. On the established transmission accurately remove a sealing ring by means of a screw-driver and establish by means of tool VW 423. In the beginning remove pipes of an exhaust system and draught of a gear change for empty seat reception.

Rod of switching of 1st, 2nd, 5th transfers and transfer of a backing with a plug of switching 2 – for assemblage dismantling/, remove / establish spring pins. 1-oj/2nd transfers it is possible to replace switching plugs separately. Replace a plug of switching of 5th transfer / of transfer of a backing only together with a ring of switching and a switching rod.

The bolt with a head under a face key for an axis of transfer of a backing 6 – 35 Н the Axis of transfer of a backing does not need to be removed m. for removal of a gear wheel of transfer of a backing.

Bolt with a head under a face key 7–25 Н m. of Vnutrennja the head party is turned to the safety mechanism of a spring / of the lock.

The lock 8 establish after installation of a shaft of switching 11 and an internal rod of switching.

Switching rod 3-ej/4th transfers and a switching plug: it is possible to replace a rod of switching or a switching plug separately. Replace the bearing of a rod of switching if it is worn out.

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Removal of bolts of a shaft of switching

Arrows specify bolts of a shaft of switching.

Position of the mechanism of a gear change

1. A rod of switching of 5th transfer / of transfer of a backing with a switching plug 2. A switching rod 3-ej/4th transfers 3. A switching plug 1-oj/2nd transfers 4. A switching shaft 5. The lock 6. An internal rod of switching

Position of the leading shaft, leading gear wheel with hollow shaft, rods of switching and вилкок switchings


These elements should be established together.

The shaft of switching and internal rod of switching can be established later.

Installation of a shaft of switching and internal rod of switching

And – a switching shaft In – an internal rod of switching

PERFORMANCE ORDER

1. Include 3rd transfer. 2. Establish a switching shaft. 3. Put an internal rod of switching In sideways on an aperture in картере the main transfer and combine it with an arm nest on a switching shaft. 4. Turn a switching rod inside in an arrow direction (fig. Installation of a shaft of switching and an internal rod of switching see).

Removal of the plug of a rod of switching

Take advantage of a hammer and an internal stripper And on 18,5–23,5 mm (for example, 1088 or Kukko 21/3).

Removal and installation of the bearing of a plug of switching

Removal and installation маслосборника

By arrow it is specified маслосборник

PERFORMANCE ORDER

1. Remove маслосборник by means of a screw-driver. 2. Insert маслосборник so deeply in картер transmissions that lock uvulas маслосборника were hooked for grooves in картере transmissions. 3. The cup маслосборника should look upwards in картере transmissions.

Installation of a sealing ring of an internal rod of switching

And = 1 mm

MECHANICAL TRANSMISSION – CARTER, GEAR WHEELS, SHAFT

Leading shaft

Leading shaft in assemblage

1. Carter of a transmission 2. The plastic plug 3. The needle bearing – a leading shaft 4. A lock ring 5. A gear wheel of 5th transfer 6. The needle bearing – 4th transfer 7. A gear wheel of 4th transfer 8. A synchronizer ring 9. Sliding муфта – 3-ja/4th transfers 10. A lock ring 11. A synchronizer nave – 3-ja/4th transfers

12. A lock ring 13. A lock ring 14. The ball-bearing – a leading shaft 15. A lock ring 16. Carter of the main transfer 17. The needle bearing – ведуший a shaft 18. A leading shaft 19. The needle bearing – 3rd transfer 20. A gear wheel of 3 transfers 21. A synchronizer ring – 3rd transfer.

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The prevention

Always replace the plastic plug 2. It is absent on the leader to a shaft on which there are lubricant apertures for 3-ej/no 4th transfers.

The needle bearing 2 is damaged at removal. Always replace it. Establish it by means of tool VW 416В on depth in 214 mm, measuring from пеоверхности картера.

Lock ring 4 – specify a demanded thickness at replacement of a gear wheel of 5th transfer.

Lock ring 10 – specify a demanded thickness at replacement of a nave of the synchronizer.

Nave of the synchronizer 11 – acting ободок it is turned to a conducted gear wheel of 3 transfers.

Lock ring 13 – if you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness.

Lock ring 15 – if you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness

The needle bearing – a leading shaft. Establish by means of the tool 40-202.

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The needle bearing of a leading shaft

Removal of the needle bearing of a leading shaft


Depth of installation of the needle bearing

And = 39,5 mm

Depth of installation is measured from a bottom edge of a verifying ruler to a bearing upper edge.

The ball-bearing

Ball-bearing installation in картер

PERFORMANCE ORDER

1. Establish a lock ring on a leading shaft. 2. Establish the ball-bearing on a leading shaft against the stop. 3. Establish a persistent heel выжимного the tool 3235 on the ball-bearing. 4. Establish выжимной the tool 3235 for шлицами a coupling disk on an entrance shaft. 5. Press on the ball-bearing having twirled two bolts In, established in deepenings of a persistent heel And. 6. Press the bearing against the stop by turns and gradually twisting two bolts.