Audi A4 1995 On 6-Speed Manual Gearbox 01E Four-Wheel Drive Workshop Manual

Description

Audi A4 1995 On 6-Speed Manual Gearbox 01E Four-Wheel Drive Workshop Manual

This Audi A4 1995 On 6-Speed Manual Gearbox 01E Four-Wheel Drive Workshop Manual is the full repair documentation for the 01E six-speed manual transmission used in four-wheel drive Audi A4 models from 1995 onward, including the S4 and RS4 with the 2.7 litre bi-turbo engine and the A4 with 1.9 l and 2.5 l TDI engines. It is Edition 04.2002, document SM-20-1, written in English across 423 pages and organised into repair groups 00 Technical data, 30 Clutch, 34 Controls and Housing, 35 Gears and Shafts, and 39 Final drive and rear differential. Every procedure, tolerance and tightening torque in the manual applies to the 01E gearbox as built, so the information matches the unit in front of you rather than a generic transmission guide.

File Details

• Manual type: Workshop / repair manual for the 6-speed manual gearbox 01E, four-wheel drive
• Coverage: Audi A4 1995 onwards, Audi S4 and Audi RS4
• Document number: SM-20-1
• Edition: 04.2002
• Language: English
• Pages: 423
• Format: PDF (instant download, printable)
• Contents: Copyright AUDI AG, Ingolstadt

Chapters Covered

• 00 – Technical data
  • Gearbox identification
  • Code letters, assignment of mechanical units, transmission ratios, capacities
  • Identification of rear final drive
  • Transmission layout
  • Calculating transmission ratio “i”
  • Repair instructions
• 30 – Clutch
  • Servicing clutch mechanism
  • Exploded view of pedal cluster (LHD vehicles)
  • Exploded view of pedal cluster (RHD vehicles)
  • Exploded view of hydraulic system
  • Removing and installing master cylinder
  • Bleeding clutch system
  • Servicing clutch release mechanism
  • Removing and installing clutch slave cylinder
  • Servicing clutch
  • Clutch for vehicles with 4 and 6-cyl. TDI engine
  • Clutch with SAC pressure plate for vehicles with 6-cyl. 2.7 l bi-turbo engine (S4 and RS4)
  • Removing and installing clutch with SAC pressure plate
  • Resetting adjuster ring of SAC pressure plate
• 34 – Controls, Housing
  • Servicing shift mechanism
  • Servicing gear stick and push rod – rear
  • Servicing selector rod, connecting rod and push rod – front
  • Removing and installing shift mechanism
  • Adjusting shift mechanism
  • Checking gear stick setting
  • Servicing shift mechanism as of 05.99 to 11.00, ident. no. 8D-X-260 001 to 8D-1-100 000
  • Servicing shift mechanism as of 11.00, ident. no. 8D-1-100 001 a
  • Removing and installing gearbox
  • Removal on vehicles with 4-cyl. TDI engine
  • Removal on vehicles with V6 TDI engine
  • Installing gearbox on vehicles with 4 and 6-cyl. TDI engine
  • Removal on vehicles with V6 bi-turbo engine (S4, RS4)
  • Fitting gearbox on vehicles with V6 bi-turbo engine (S4, RS4)
  • Checking gear oil level in manual gearbox
  • Removing and installing oil pipes
  • Removing and installing oil pump
  • Servicing oil pump
  • Dismantling and assembling gearbox
  • Removing and installing bearing housing, Torsen differential and end cover
  • Removing and installing manual gearbox and selector shaft
  • Removing and installing 5th and 6th gear
  • Removing and installing input shaft, drive pinion, hollow shaft and gearbox shift mechanism
  • Dismantling and assembling bearing housing
  • Servicing bearing system for Torsen differential
  • Servicing end cover
  • Servicing bearing plate
  • Re-determining shim “S4”
  • Servicing gearbox housing
  • Dismantling and assembling selector shaft as complete unit
• 35 – Gears, Shafts
  • Dismantling and assembling input shaft
  • Dismantling and assembling drive pinion and hollow shaft
  • Optimised synchronisation for 1st and 2nd gear on gearboxes with code letters FZV, FZW and FZY
• 39 – Final drive, Differential rear
  • Replacing oil seal for flange shaft
  • Removing and installing speedometer sender G22 and drive wheel
  • Replacing oil seal and grooved ball bearing for propshaft flange at gearbox
  • Removing and installing differential
  • Dismantling and assembling differential (gearbox with no oil pump)
  • Dismantling and assembling differential (gearbox with oil pump)
  • Adjusting drive pinion and crown wheel
  • Adjusting drive pinion
  • Adjusting crown wheel
  • Servicing propshaft
  • Checking gear oil level in rear final drive
  • Removing and installing thrust tube
  • Dismantling and assembling thrust tube
  • Replacing oil seals for flange shafts
  • Removing and installing rear final drive
  • Dismantling and assembling rear final drive
  • Removing, installing, dismantling and assembling drive pinion

Read as a whole, the manual gives a technician a complete path through the 01E transmission: identifying which code letter gearbox is in the car, pulling it out of a 4-cylinder TDI, V6 TDI or V6 bi-turbo engine bay, stripping it to the last shaft and synchro-ring, and then putting it back together with the shim thicknesses, bearing pre-loads and friction torque values that the unit actually needs. It is not limited to a single job. It covers the clutch hydraulics and pedal cluster at one end and the rear final drive, propshaft and thrust tube at the other, and treats the Torsen differential, the oil pump circuit on cooled gearboxes, and the three different shift mechanism generations as separate servicing topics rather than footnotes.

Technical Data and Adjustment Values

The opening repair group establishes the identity data you need before ordering anything. Gearbox code letters covered by the manual are DQT, DSY, EDU, EHW, FDP, FRQ, FTF, FTG, FTK, FTU, FZV, FZW and FZY, with manufacture dates and model assignments listed alongside each one. Final drive ratio is given as 37 : 9 = 4.111 for the majority of applications. Gear oil specification is G 052 911 A SAE 75 W 90 synthetic, with capacities of 2.5 litres or 3.4 litres depending on version, the larger figure including 0.3 litres for the gear oil cooler and pipes on S4 and RS4 units. The rear final drive 01H is documented separately with its own code letters DQA and DAK, a 1.9 litre capacity and GL 5 SAE 90 oil.

Adjustment work is dealt with in real depth. Shim positions S1 and S2 set crown wheel pre-load in the differential cover and gearbox housing, while S3 and S4 set drive pinion pre-load in the gearbox housing and bearing plate. The manual walks through determining total shim thickness with a dial gauge and universal mandrel, dividing it correctly, then verifying the result with a friction torque reading taken on a 0 to 600 Ncm gauge. Friction torque windows are stated separately for new and used bearings, and the text explains why low-friction taper roller bearings must not be given extra oil before measurement.

Who This 01E Gearbox Manual Is For

Anyone rebuilding, resealing or replacing an 01E in an A4, S4 or RS4 will find the sequence the manual expects: drain and identify, support the engine and gearbox correctly, lower the subframe only as far as the stated dimension allows, and disconnect the shift mechanism without destroying the ball end on the older connecting rod. That last warning appears repeatedly in the removal sections because the older style connecting rod cannot be separated from the selector rod without ruining it, and the manual tells you so before you start pulling.

Gearbox specialists get the internal detail: the order for splitting the bearing housing from the end cover, handling the coil spring and dished washer, extracting the Torsen differential, removing the multi-point socket-head bolt in the input shaft, and pressing off and on the synchro-hubs, gear wheels and bearing inner races. Owners working on a single fault get the targeted sections: gear oil level checks, oil seal replacements, speedometer sender and drive wheel, propshaft radial run-out measurement and adjustment, and the shift mechanism adjustment dimensions for each of the three production periods.

Special Tools and Workshop Practice

The manual names the tooling it expects, including VW 540 for mounting the gearbox on a stand, VW 402, VW 407, VW 412 and VW 415 A press tooling, VW 681, VW 771 with attachments, the 3282 gearbox mount and 3282/12 adjustment plate on V.A.G 1383 A, plus 30-211 A support bridge, 3116 clamping sleeve and 3276 for spring pin work. It also lists the sealing compounds and greases used during assembly, among them AMV 188 000 02 and AMV 188 001 02 sealing paste, G 052 128 A1 sealing grease, G 052 142 A2 polycarbamide grease, G 000 100 for input shaft splines and lithium grease G 052 150 A2 for the slave cylinder boot. Tightening torques are given in table form throughout, and the general repair instructions at the front explain how to handle circlips, spring pins, self-locking fasteners, shims, bearings and sealants correctly.

The level of specification is what separates a successful rebuild from a transmission that whines, jumps out of gear or leaks within a few thousand miles. Bearing pre-load set by eye, a synchro-ring fitted the wrong way round, a shim chosen by guesswork or a propshaft refitted without its balance mark will all cause problems that no amount of fresh oil will fix. This manual supplies the measured values, installation positions and assembly sequence that avoid those outcomes, and it does so for the specific 01E unit rather than a family of unrelated gearboxes.

IMAGES PREVIEW

Delivery is instant. The Audi A4 1995 On 6-Speed Manual Gearbox 01E Four-Wheel Drive Workshop Manual arrives as a PDF download immediately after payment, with no shipping and no waiting. Keep it on a laptop, tablet or phone in the workshop, print the pages for the job in front of you, and work from the same reference on the next 01E that comes through the door.