Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSAUDI2009A6 BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 20 (5-SPEED MANUAL TRANSMISSION 01A)
2009 Audi A6 Base
Section 20 (5-Speed Manual Transmission 01A)
2009 Audi A6 BaseSECTION Section 20 (5-Speed Manual Transmission 01A)
WARNING: This page is about a different car, the 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
- 00 General, Technical data
- 30 Clutch
- Clutch mechanism components (on chassis)
- Clutch release mechanism components (on transmission), servicing
- Clutch, servicing
- 34 Manual Transmission - Controls, Housing
- Shift mechanism, servicing
- Shift mechanism, servicing
- Shift mechanism, installation position
- Gear shift knob and cover, removing and installing
- Gear shift and rear push rod, servicing
- Selector rod and front push rod, servicing
- Gear shift and rear push rod, removing and installing
- Shift mechanism, removing and installing
- Shift mechanism, adjusting
- Shift adjustment, checking
- Transmission, removing and installing
- Torsen differential housing, removing and installing
- Transmission oil level, checking
- Transmission, disassembling and assembling
- Transmission, disassembling and assembling
- Transmission, assembly overview
- Transmission, sub-assembly overviews
- Ball bearing for input shaft and multi-function sensor, removing and installing
- Input shaft, pinion, hollow shaft, selector rods, transmission cover and Torsen differential housing, removing and installing
- Ball bearing for input shaft, multi-function sensor, pinion, selector rods, transmission cover and Torsen differential housing, removing and installing
- Torsen differential housing, servicing, and Torsen differential, removing and installing
- Torsen differential housing, servicing, and Torsen differential, removing and installing
- Notes
- Removing sealing cap
- Removing and installing drive flange
- Pressing out Torsen differential
- Pressing off ball bearing of Torsen differential
- Pressing ball bearing onto Torsen differential
- Pressing out ball bearing for drive flange
- Pressing in ball bearing for drive flange
- Extracting needle bearing
- Installation position of front needle bearing
- Installation position of rear needle bearing
- Pressing in needle bearing
- Pressing in Torsen differential
- Driving in oil seal
- Torsen differential housing, servicing, and Torsen differential, removing and installing
- Transmission shift mechanism, disassembling and assembling
- Transmission shift mechanism, disassembling and assembling
- Notes
- Installation position of 5th and reverse gear selector fork and of driver for selector rod
- Removing and installing ball sleeve
- Pulling out mounting bushing for 3rd and 4th gear selector rod
- Driving in mounting bushing for 3rd and 4th gear selector rod as far as it will go
- Installation position of oil seal
- Installation position of shift mechanism assembly in transmission
- Removing and installing locking unit for 5th gear and reverse gear
- Assembling locking unit
- Transmission shift mechanism, disassembling and assembling
- Shift mechanism, servicing
- 35 Manual Transmission - Gears, Shafts
- Input shaft, disassembling and assembling
- Notes
- Locking bolt for needle bearing
- Extracting needle bearing
- Installation position of needle bearing
- Pressing in needle bearing
- Driving oiling sleeve into input shaft
- Extracting roller sleeve
- Installation position of roller sleeve
- Driving in roller sleeve
- Pressing out 5th gear wheel
- Pressing out 3rd and 4th gear synchro-hub
- Inserting spring into sliding gear
- Checking synchro-ring for wear
- Installation position of circlips
- Determining circlip
- Available circlips for 3rd and 4th gear synchro-hub
- Pressing on 3rd and 4th gear synchro-hub
- Installation position of locking collar
- Pressing on 5th gear wheel
- Input shaft, adjusting
- Pinion and hollow shaft, disassembling and assembling
- Pinion and hollow shaft, disassembling and assembling
- Notes
- Extracting outer race for double tapered roller bearing
- Pressing off inner race for double tapered roller bearing
- Pressing in outer race for double tapered roller bearing
- Pressing on inner race for double tapered roller bearing
- Determining circlip
- Pulling out locking bushing for outer race of small tapered roller bearing
- Pressing out outer race for tapered roller bearing
- Pressing in outer race for tapered roller bearing
- Pressing off inner race for tapered roller bearing
- Pressing on inner race for tapered roller bearing
- Pressing off 5th gear and reverse gear synchro-hub
- Pressing off 4th gear wheel
- Pressing off 3rd gear wheel
- Pressing off 1st and 2nd gear synchro-hub
- Installation position of circlips
- Inserting spring into sliding gear
- Checking synchro-ring for wear
- Pressing on synchro-hub for 1st and 2nd gear
- Installation position of locking collar for 1st and 2nd gear
- Pressing on 3rd gear wheel
- Pressing on 4th gear wheel
- Pressing on synchro-hub for 5th gear and reverse gear
- Installation position of locking collar for 5th gear and reverse gear
- Locking collar assignment to reverse idler gear
- Pinion and hollow shaft, disassembling and assembling
- Reverse idler gear, removing and installing
- Input shaft, disassembling and assembling
- 39 Final drive, Differential
- Oil seal for drive flange, replacing
- Speedometer vehicle speed sensor and drive-wheel, removing and installing
- Oil seal for drive flange/drive shaft, replacing
- Differential, removing and installing
- Differential, disassembling and assembling
- Differential, disassembling and assembling
- Notes
- Extracting tapered roller bearing outer race from transmission housing
- Pressing tapered roller bearing outer race into transmission housing
- Extracting inner race for right tapered roller bearing
- Pressing on inner race for right tapered roller bearing
- Extracting inner race for left tapered roller bearing
- Mounting inner race for left tapered roller bearing
- Driving outer race of left tapered roller bearing out of cover
- Driving outer race of left tapered roller bearing into cover
- Driving ring gear out of housing
- Heating ring gear to approx. 100 ° C and installing
- Installing bevel gears
- Removing and installing spring pin
- Differential, disassembling and assembling
- Pinion and ring gear, adjusting
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.