012 Manual Transmission Revisions (GROUP 34, NO. 96-02)

012 MANUAL TRANSMISSION REVISIONS

TECHNICAL SERVICE BULLETIN

012 MANUAL TRANSMISSION, REVISIONS

Model(s): 1996-on Audi A4

Group: 34 - Manual Transmission - Controls, Case

Bulletin No.: 96-02

Date: January 22, 1996

SERVICE INFORMATION

This Technical Bulletin contains repair information from three different repair groups. It will be integrated into the repair manual at the next printing.

The information in this Technical Bulletin replace the following pages in the current repair manual:

Repair Group 00 - page 00-3

Repair Group 34 - all pages from 34-18

Repair Group 39 - all pages

CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, CAPACITIES

Manual Transmission Transmission Code Letters	5-speed 012 CTJ	5-speed 012 CWZ
Manufactured from	11.94	1.95
Application Model	Audi A4 1996-on	Audi A4 1996-on
Engine	2.8 ltr. - 128 kW	2.8 ltr.- 128 kW
Ratio: Z2:Z1
Final drive	37 : 10 = 3.700	37 : 10 = 3.700
1st gear	35 : 10 = 3.500	35 : 10 = 3.500
2nd gear	35 : 19 = 1.842	35 : 18 = 1.944
3rd gear	39 : 30 = 1.300	39 : 30 = 1.300
4th gear	33 : 35 = 0.943	33 : 35 = 0.943
5th gear	30 : 38 = 0.789	30 : 38 = 0.789
Reverse	31 : 9 = 3.444	31 : 9 = 3.444
Speedometer	electronic	electronic
Capacity	2.25 liters(2.4 qt)	2.25 liters(2.4 qt)
Specification	Gear oil G 52 SAE 75 W 90 (synthetic oil) (*2)	Gear oil G 52 SAE 75W 90 (synthetic oil) (*2)
Clutch Control	hydraulic	hydraulic
Clutch Plate Diameter	240 mm (9.45 in.)	240 mm (9.45 in.)
Drive Shaft Flange Diameter	130 mm (*1) (5.12 in.)	130 mm (*1) (5.12 in.) (*1)
Overall Ratio In High Gear	2.921	2.921
NOTE: (*1)= Tripod drive shafts (*2)= Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part: Container 0.5 ltr. (0.53 qt.) - P/N G 052 145 A1 Container 1.0 ltr. (1.06 qt.) - P/N G 052 145 A2

TRANSMISSION OIL, CHECKING LEVEL

- The transmission oil is at the correct level if it is filled even with the lower edge of the oil filler hole.

- Remove oil filler plug -arrow- to check oil level. See Fig 1 . Fill if needed.

- Install plug and tighten to 25 N.m (18 ft-lb).

LIST OF COMPONENTS

Refer to Fig 2 .

1 - 1st gear

2 - 2nd gear

3 - 3rd gear

4 - 4th gear

5 - 5th gear

6 - Reverse gear

7 - Transmission housing

8 - Transmission cover

9 - Input shaft

10 - Drive pinion

11 - Ball bearing

12 - Differential

13 - Tapered roller bearing

14 - Tapered roller bearing

TRANSMISSION HOUSING, DISASSEMBLING AND ASSEMBLING

Refer to Fig 3 .

1. Transmission housing;
   • Clamp transmission in repair stand. See Fig 4 .
   • Remove flange shaft seal with VW 681 extractor lever, install with VW 195 arbor 5.5 mm (0.217 in.) below surface of transmission housing.
   • Pay attention to breather sleeve insertion depth. See Fig 8 .
   • Remove tapered roller bearing, right, outer race, See Fig 17 ; install with 30-205 thrust pad and VW 295 drift.
   • Remove tapered roller bearing, left, See Fig 14 ; install with WV 472/1 and VW 408a.
   • Remove bushing for 3rd and 4th gear shift rod. See Fig 9 .
   • Install bushing with VW 295 drift and VW 295 adapter tool.
   • Remove and install needle bearing for input shaft.
   • Seal with AMV 188 200 sealing paste.
2. Screw;
   • Tightening torque: 25 N.m (18 ft-lb)
3. Locking plate;
   • For multi-function switch.
4. Multi-function switch;
5. Right drive flange shaft;
   • Insert with VW 295 needle bearing drift.
     NOTE: *  Flange shafts with polygon bearing are installed in all transmissions.

     • Rough running of the polygon bearing when flange shaft is not installed is not an indication of a faulty bearing. An acoustic check can only be conducted with shaft in installed position.
     • For flange shaft with a spline diameter of 30 mm a spacer ring must be installed.
6. Circlip;
   • Always replace.
   • Removing and installing, See Fig 11 .
7. Lock for 5th and reverse gear;
   • Can be replaced with transmission installed.
   • Tightening torque for securing bolts: 10 N.m (7 ft-lb)
   • Position beveled side of plastic bushing facing bore for relay shaft.
8. Cover for shift shaft;
   • Tightening torque for securing bolt 20 N.m (15 ft-lb)
9. Connector for multi-function switch;
10. Torx bolt;
    • Tightening torque: 10 N.m (7 ft-lb)
11. Differential;
    • Can be removed without removing transmission.
12. Final drive cover;
    • Removing and installing outer race of tapered roller bearing, see Fig 14 and Fig 15 .
    • Remove seal with VW 681 extractor lever.
    • Seal with AMV 188 200 03 sealing paste.
13. Circlip;
    • Always replace.
    • Removing and installing, See Fig 11 .
14. Left drive flange;
    • Removing, See Fig 10 .
    • Install with VW 295 needle bearing drift
    • See NOTE, item 5.
15. Torx bolt;
    • Tightening torque: 25 N.m (18 ft-lb)
16. Seal;
17. Vehicle speed sensor;
    • Can be replaced with transmission installed. See Fig 20 .
      NOTE: Handle vehicle speed sensor with care; do not drop. Damage could result in false speedometer readings.
18. Drive gear for speedometer;
    • Can be replaced with transmission installed. See Fig 12 .
19. Circlip;
    • Record thickness after removing.
20. Input shaft bearing;
    • Removing from transmission housing, See Fig 5 .
    • Installing, See Fig 6 .
21. Circlip;
    • Record thickness after removing.
22. Belleville spring washer;
    • Small diameter faces guide sleeve (convex side).
23. Guide sleeve with seal;
24. Torx bolt;
    • Tightening torque: 25 N.m (18 ft-lb)