Audi 80/Avant (B4)

since 1991-1995 release

Repair and operation of the car



Audi 80/Avant
+ Technical specification
+ Engines
+ System of production of the fulfilled gases
+ Cooling system
+ Fuel tank and fuel pump
+ Air filter and airintaking channels
+ System of injection
+ Coupling
- Transmission and transmission
   Removal and installation of the mechanical transmission (T)
   Noise in the transmission
   Automatic Transmission (AT)
   Electronic control of AKP
   Main transfer
   Power shafts
   Check of cuffs of power shafts
   List of malfunctions
+ Suspension bracket and steering
+ Brake system
+ Anti-blocking system of brakes
+ Wheels and tires
+ Body electrical system
+ System of ignition
+ Lighting
+ Signaling devices
+ Devices and auxiliary devices
+ Heating and ventilation
+ Body elements
+ Search of malfunctions
+ Specifications





List of malfunctions

Power shafts

Cuffs (arrow) on cardan hinges of both power shafts should not have cracks or other damages. Water and dirt are dangerous to the cardan hinge.


Usually with power shafts there are no problems. The term of their service, naturally, depends on style of driving. Sharp starts with the turned-out forward wheels and start-off from the place with pro-slipping lead to premature breakages of hinges.
  • Hinges of power shafts suddenly show signs of malfunctions which, however, soon can disappear again completely. "The quiet phase" can proceed many days or kilometers.
  • Rhythmic noise of a beating or knock when pressing a pedal of an accelerator are characteristic or at the movement in the mode of compulsory idling (setup). If noise change depending on turn of a wheel, then, most likely, the external hinge (is faulty from a wheel).
  • Vibrations and trembling of a steering wheel at the turned wheels also indicate the faulty external hinge.

Removal of a forward power shaft

You will need a new six-sided bolt with not falling down lock element for the external hinge of a power shaft, самоконтрящаяся a nut for connecting draft of the stabilizer, and also sealing laying for the internal hinge of a shaft (laying is not necessary at the 6-cylinder engine with mechanical and automatic transmissions).

 PERFORMANCE ORDER

  1. To take off a wheel cap.
  2. To weaken wheel bolts.
  3. To weaken a six-sided bolt in a wheel nave; for this purpose the car has to be fixed.
  4. To raise the car in front and to zfiksirovat it.
  5. To remove a wheel.
  6. To turn off stabilizer nuts on the right and at the left.
  7. To squeeze out the stabilizer upward.
  8. In the presence – to remove protection of the transmission.
  9. To turn out bolts with vnutrenniy a hexagon, fixing a shaft to the transmission.
  10. To wring out a power shaft from a transmission flange.
  11. On models with ABS to delay a little back the speed sensor.
  12. For removal of a shaft respectively to turn out steering.
  13. Installation: to establish new sealing laying on the internal hinge. For this purpose to remove a protective film from laying.
  14. At first to insert a shaft from a wheel. Then crosswisely to tighten fixing bolts on a drive flange from the transmission (M8 bolts: 45 N • m; M10 bolts: 80 N • м). Do not forget sealing laying!
  15. To lower the car, to block wheels. To tighten new bolts of a nave of wheels as follows:
  16. Bolt of M14 x 1,5: to tighten the moment 120 N • m and to tighten in conclusion for 1/4 (90 °).
  17. Bolt of M16 x 1,5: to tighten the moment 200 N • m and to tighten in conclusion for 1/4 (90 °).
  18. To tighten nuts on on connecting draft of the stabilizer the moment of 20 N • m.
  19. On models with ABS manually to push the speed sensor against the stop.

Removal of a back power shaft

You will need a new six-sided bolt with not falling down lock element for the external hinge of a power shaft, and also sealing laying for the internal hinge of a shaft (laying only for models with 5-and 6-cylinder engines).

 PERFORMANCE ORDER

  1. To take off a wheel cap.
  2. To weaken wheel bolts.
  3. To weaken a six-sided bolt in a wheel nave; for this purpose the car has to be fixed.
  4. To raise the car behind and to fix it.
  5. To remove a wheel.
  6. To turn out bolts with the internal hexagon fixing a shaft to differential of the back bridge.
  7. To wring out the driveshaft from a drive flange at the transmission.
  8. To delay a little back the ABS system speed sensor.
  9. To take out a shaft.
  10. Installation: to establish new sealing laying on the internal hinge. For this purpose to remove a protective film from laying.
  11. At first to insert a shaft from a wheel. Then crosswisely to tighten fixing bolts on a drive flange from the inside (M8 bolts: 45 N • m; M10 bolts: 80 N • м). Do not forget sealing laying!
  12. To lower the car, to block wheels. To tighten a new bolt of a nave of a wheel as follows:
  13. Bolt of M14 x 1,5: to tighten the moment 120 N • m and to tighten in conclusion for 1/4 (90 °).
  14. Bolt of M16 x 1,5: to tighten the moment 200 N • m and to tighten in conclusion for 1/4 (90 °).
  15. To tighten nuts on on connecting draft of the stabilizer the moment of 20 N • m.
  16. To manually push the ABS system speed sensor against the stop.

 Hint: do not move cars with the removed driveshaft; otherwise the wheel bearing is damaged. At emergency situation it is necessary to install only the external hinge.

On the Audi cars various power shafts depending on type of the engine and the transmission are established. Therefore upon purchase of spare parts have at yourself marking of the engine and identification number of the car.

Removal of the external hinge

All models

External hinge of a power shaft:

1 – lock ring;
2 – expansion washer;
3 – dish-shaped spring.


 PERFORMANCE ORDER

  1. To remove a power shaft.
  2. If a cuff as it should be, it is necessary to unbend a big collar, to remove back a protective cuff.
  3. If the cuff is damaged, it is necessary to remove it completely.
  4. To make from within on the hinge strong blow by the aluminum or plastic hammer and thus to shift the hinge from a shaft.
  5. Before installation of the new hinge to insert a new lock ring into a groove of the leading shaft.
  6. To establish a dish-shaped spring and an expansion washer in case they were established in the corresponding version of a power shaft as it is shown in the drawing. Do not forget rubber cuffs.
  7. At installation to get the hinge on a shaft by means of the plastic hammer until the lock ring is recorded.
  8. To grease the hinge: on the new hinge with an external diameter of 81 or 88 mm 90 g of plastic MoS2 lubricant (VW G 6), at the same time 40 g in the hinge and 50 g in a cuff are necessary.
  9. On hinges with an external diameter of 98 mm the bigger amount of lubricant is necessary: 120 g of plastic MoS2 lubricant (VW G 6), at the same time 80 g in the hinge and 40 g in a cuff.
  10. If already used hinges are installed, it is necessary to add lubricant to them only.
  11. It is strong to squeeze cuff collars.

Removal of the internal hinge

Gomokinetichesky hinge

Internal hinge (2):

1 – lock washer;
3 – power shaft.


 PERFORMANCE ORDER

  1. To remove a power shaft.
  2. By means of two narrow screw-drivers it is patient to take a lock ring from a groove on the end of a shaft and to remove it.
  3. Now to pull together the hinge from a shaft; if necessary to help itself the plastic or aluminum hammer.
  4. If the hinge does not manage to be removed from a shaft, it should be wrung out by means of a repair press in a workshop.
  5. At installation at first to put on a cuff.
  6. If in your car there is a hinge with a dish-shaped spring, then before installation it is necessary to put on a spring a shaft or to check its situation: on an outer edge it has to be camber towards the hinge.
  7. To put on the hinge a half shaft, to establish a lock ring.
  8. The lock ring in itself will not get to a groove therefore it is necessary to clamp a half shaft in a vice, to establish a big replaceable face head or a piece of a pipe over an internal part of the hinge and to strike sharply it with the hammer. The hinge will a little move back, bending a spring, and the lock ring will enter a groove.
  9. Grease the hinge: on the new hinge with an external diameter of 90 or 100 mm 90 g of plastic MoS2 lubricant (VW G 6), at the same time 40 g in the hinge and 50 g in a cuff are necessary.
  10. On hinges with an external diameter of 108 mm the bigger amount of lubricant is necessary: 120 g of plastic MoS2 lubricant (VW G 6), at the same time 35 g in the hinge and 85 g in a cuff.
  11. If already used cardan hinges are installed, it is necessary to add lubricant to them only.
  12. Before screwing up of the hinge (or a cuff flange) apply on a sealing surface between a flange of a cuff and the hinge the condensing means of VW D 3.

Removal of the internal hinge

Tripod hinge

The cardan hinge "Tripod" (1) cannot be separated from the leading half shaft. Gomokinetichesky hinges, on the contrary, can be removed from actually power shaft (3) – both external (2), and internal (4).


 PERFORMANCE ORDER

  1. Tripod hinges cannot be separated from a power shaft. As spare parts they are delivered complete with a half shaft and a protective cuff. Thus, when replacing it is necessary to remove the external hinge and to replace a shaft with the internal hinge.
  2. If only the protective cuff of the Tripod hinge is defective, then at first it is necessary to remove the external hinge. On the cleared power shaft the cuff can be shifted to the Tripod hinge. Critical point: the cuff needs to be raised over a ledge in the middle of a shaft. For this purpose grease a ledge with jellied lubricant and raise a cuff over a thickening by means of the blunt round tool (the spoon handle).
  3. In the hinge there are 140 g of jellied G 000 605 lubricant. When replacing a cuff it is necessary to add only a little lubricant.







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