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 23 (6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE)
2009 Audi A6 Base
Section 23 (6-Speed Manual Transmission 02X, Four-Wheel Drive)
2009 Audi A6 BaseSECTION Section 23 (6-Speed Manual Transmission 02X, Four-Wheel Drive)
WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
- 00 Technical data
- 30 Clutch
- Clutch mechanism, servicing
- Clutch mechanism, servicing
- Pedal cluster (LHD vehicles), assembly overview
- Clutch pedal switch F36, removing and installing
- Clutch Pedal Starter Interlock Switch F194, removing and installing
- Over-center spring, removing and installing
- Pedal cluster (RHD vehicles), assembly overview
- Hydraulic system, assembly overview
- Notes on removing and installing master cylinder and slave cylinder
- Master cylinder, removing and installing
- Clutch hydraulic system, bleeding
- Clutch release mechanism, servicing
- Clutch, servicing
- Clutch, servicing
- Conventional clutch, servicing
- Self-adjusting clutch (Sachs version), servicing
- Self-adjusting clutch (Sachs version), removing and installing
- Clutch with SAC pressure plate (LuK version), servicing
- Clutch with SAC pressure plate, removing and installing
- Adjuster ring in SAC clutch pressure plate, resetting
- Clutch mechanism, servicing
- 34 Controls, housing
- Selector mechanism, servicing
- Transmission, removing and installing
- Transmission mounts, removing and installing
- Transmission oil
- Transmission, mounting on assembly stand
- Transmission, disassembling and assembling
- Transmission, general layout
- Assembly overview
- Ball bearing for input shaft, transmission cover, bearing housing and selector shaft, removing and installing
- Torsen housing and Torsen differential, removing and installing
- 3rd to 6th gear, removing and installing
- Input shaft, pinion shaft/hollow shaft, reverse gear wheel and reverse selector gear, removing and installing
- Disassembling and assembling sequence
- Torsen housing, disassembling and assembling
- Transmission cover, servicing
- Transmission cover, servicing
- Notes
- Pressing needle bearing out of transmission cover
- Pressing needle bearing into transmission cover
- Pulling out ball sleeve - C - from transmission cover
- Driving ball sleeve into transmission cover until flush
- Pulling out needle roller bearing from transmission cover
- Carefully press in new needle roller bearing into transmission cover until limit stop.
- Securing needle roller bearing and needle bearing in transmission cover.
- Transmission cover, servicing
- Bearing housing, servicing
- Bearing housing, servicing
- Notes
- Driving outer race for needle roller bearing out of bearing housing
- Pressing outer race for needle roller bearing into bearing housing until limit stop
- Pulling front ball sleeve out of reverse gear selector rod
- Pressing front ball sleeve into reverse gear selector rod until limit stop.
- Pulling out rear ball sleeve for reverse gear selector rod
- Pressing in rear ball sleeve - A - for reverse gear selector rod
- Driving in ball sleeve for selector rod for 3rd and 4th gear
- Removing and installing locking bushing for selector rod
- Bearing housing, servicing
- Transmission housing, servicing
- Transmission housing, servicing
- Notes
- Pulling out oil seal for selector shaft with transmission disassembled
- Installing oil seal - C - with selector shaft installed
- Driving in seal for selector shaft
- Removing and installing locking bushing for selector rod
- Pulling out ball sleeve - C - from transmission housing.
- Driving out input shaft needle bearing from transmission housing
- Pressing in input shaft needle bearing until limit stop
- Securing input shaft needle bearing
- Removing selector shaft ball sleeve
- Driving in ball sleeve for selector shaft
- Transmission housing, servicing
- Selector shaft, oil seal and back-up light switch F4, servicing
- Selector shaft, oil seal and back-up light switch F4, servicing
- Selector shaft, removing and installing (with transmission installed)
- Selector shaft oil seal, replacing (with transmission removed) (transmission remains assembled)
- Selector shaft oil seal, replacing (with transmission installed)
- Back-up light switch F4, removing and installing
- 35 Gears, shafts
- Input shaft
- Input shaft, adjusting
- Pinion shaft and hollow shaft
- Pinion shaft and hollow shaft, assembly overview
- Pinion shaft and hollow shaft, disassembling and assembling
- Notes
- Pulling out double tapered roller bearing outer race
- Pressing off double tapered roller bearing inner race
- Pressing on double tapered roller bearing inner race
- Determining thickness of circlip
- Heating transmission housing in order to install double tapered roller bearing outer race
- Pressing in double tapered roller bearing outer race
- Pulling tapered roller bearing outer race out of bearing housing
- Pressing tapered roller bearing outer race into bearing housing
- Disassembling and assembling hollow shaft
- Pressing off thrust washer for reverse selector gear
- Pressing off tapered roller bearing inner race with 2nd speed selector gear
- Pressing off 1st and 2nd gear synchronizing hub
- Installation position of circlips
- Installation position of synchronizing rings for 1st and 2nd gear:
- Checking 1st gear inner ring for wear
- Checking 1st and 2nd gear intermediate ring for wear
- Pressing on 1st and 2nd gear synchronizing hub
- Assembling 1st and 2nd gear locking collar/synchronizing hub
- Pressing on tapered roller bearing inner race
- Checking axial play of selector gears
- Pressing on thrust washer for reverse selector gear
- 39 Final drive - front differential
- Flange shaft oil seal, replacing
- Differential, removing and installing
- Differential, removing and installing
- Notes
- Removing flange shaft (left-side)
- Remove right flange shaft
- Removing and installing circlip
- Installing spacer ring
- Flange shaft assembly
- Removing flange shaft oil seal (left-side)
- Installing flange shaft oil seal (left-side)
- Removing flange shaft oil seal (right-side)
- Installing flange shaft oil seal (right-side)
- Differential, removing and installing
- Differential, disassembling and assembling
- Differential, disassembling and assembling
- Notes
- Pulling tapered roller bearing outer race (right-side) out of transmission housing
- Driving outer race for tapered roller bearing (right-side) into transmission housing
- Pulling off inner race for tapered roller bearing (right-side)
- Pressing on tapered roller bearing inner race (left and right)
- Pulling off inner race for tapered roller bearing (left-side)
- Pulling tapered roller bearing outer race (left-side) out of cover for final drive
- Pressing tapered roller bearing outer race (left-side) into cover for final drive.
- Driving ring gear off cage
- Heating ring gear to approx. 100° C and installing
- Installing differential bevel gears
- Differential, disassembling and assembling
- Pinion shaft and ring gear, adjusting
RENDER: 1.0x
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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.