Audi 4000 Sedan, Coupe Repair & Service Manual 1980-1987

• Audi Sedan 1.6L, 1.7L, 1.8L 4-Cylinder
• Audi S and 5+5 Sedan 2.2L 5-cylinder
• Audi 2.2L Coupe, 5-cylinder

GENERAL DESCRIPTION

Either a four or five-speed transmission is fitted according to model, and there are two variations of each transmission, as listed in the Specifications.

The transmission is bolted to the rear of the engine in conventional manner, but because of front wheel drive configuration, drive is transmitted to a differential unit located at the front of the transmission and then through the driveshafts to the front wheels.

All forward gears incorporate synchromesh engagement, and reverse gear is obtained by engaging a spur type idler gear with 1st/2nd synchro sleeve on the output shaft and a spur gear on the input shaft (see photo).

Gearshift is by means of a floor mounted lever, and a single rod and linkage clamped to the selector rod which protrudes from the rear of the transmission. The selector rod incorporates a finger which engages the other selector rods in the bearing carrier.

When overhauling the transmission, due consideration should be given to the costs involved, since it is often more economical to obtain a service exchange or a good secondhand transmission rather than fit new parts to the existing transmission.

Repairs to the differential are not covered here, as the special instrumentation required is not normally available to the home mechanic.


REMOVAL AND INSTALLATION

1. Position the front of the car over an inspection pit or on car ramps and apply the handbrake firmly.



2. Disconnect the battery negative cable.



3. Unscrew and remove the upper bolts attaching the transmission to the engine, noting the location of any brackets.



4. Disconnect the wiring to the reversing light switch and release the cable clip.



5. Unscrew the nut and disconnect the speedometer cable from the differential cover or transmission, as applicable.



6. Detach the clutch cable from the transmission (refer to Chapter 5).



7. Remove the front exhaust downpipe from the manifold and exhaust system (refer to Chapter 3).



8. On five-cylinder models only, remove the air cleaner (Chapter 3), and also support the front of the engine with a hoist or bar similar to that shown in Figure 6.1.



9. Disconnect the driveshafts from the drive flanges (refer to Chapter 8) and tie them to one side.



10. On four-cylinder models only, unbolt and remove the center engine mounting bracket.



11. Unbolt and remove the transmission front cover.



12. Remove the starter motor (refer to Chapter 10).



13. On five-cylinder models only, disconnect the steering tie-rod bracket from the steering gear (refer to Chapter 11).



14. Support the transmission with a trolley jack or stand.



15. Unscrew the lockbolt securing the selector adapter to the selector rod on the rear of the transmission (see photo). On four-speed transmissions it will be necessary to first remove the locking wire.



16. Press the support rod from the balljoint and withdraw the adapter from the selector lever.



17. Unscrew and remove the lower bolts attaching the transmission to the engine.



18. Loosen the bolt securing the transmission stay to the underbody. Unscrew and remove the stay inner bolt and pivot the stay from the transmission.



19. Unbolt the bonded rubber mounting from the transmission.



20. On four-cylinder models only, unbolt and remove the front transmission support bracket.



21. With the help of an assistant, withdraw the transmission from the engine, making sure that the input shaft does not hang on the clutch. Lower the transmission to the ground.



22. Installation is a reversal of removal, but lightly lubricate the splines of the input shaft with molybdenum disulphide powder or paste, and make sure that the engine/transmission mountings are free of strain; if necessary refer to Chapter 1 for the correct alignment procedure.
    
    Where applicable secure the selector adaptor lockbolt with new locking wire. Adjust the gear lever and linkage as described in Section 10 or 20. Check, and if necessary, top up the oil level.

• Introduction to the Audi 80 and 4000; Vehicle identification numbers; Buying parts; Maintenance techniques, and more
• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams