Audi 80/Avant (B4)

since 1991-1995 of release

Repair and car operation



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
+ injection System
+ Coupling
- Transmission and transmission
   Removal and installation of a mechanical transmission (KP)
   Noise in a transmission
   Automatic transmission (AKP)
   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 electrosystem
+ ignition System
+ Lighting
+ Signalling devices
+ Devices and auxiliary devices
+ Heating and ventilation
+ body Elements
+ Search of malfunctions
+ Specifications





List of malfunctions

Power shafts

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


Usually with power shafts there are no problems. Term of their service, naturally, depends on style of driving. Sharp starts with the turned-out forward wheels and a troganiye from a place with pro-slipping lead to premature breakages of hinges.
  • Hinges of power shafts suddenly show signs of malfunctions which, however, soon can disappear completely again. «The quiet phase» can proceed many days or kilometers.
  • Rhythmic noise of palpation or knock are characteristic by pressing a pedal of an accelerator or at movement in a mode of compulsory idling (nakaty). If noise change depending on wheel turn, the external hinge (most likely, 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 remove a wheel cap.
  2. To weaken wheel bolts.
  3. To weaken a six-sided bolt in a wheel nave; for this purpose the car should be fixed.
  4. To raise the car in front and зфиксировать 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. At existence – to remove protection of a transmission.
  9. To turn out bolts with vnutrenniy a shestigrannik, fixing a shaft to a transmission.
  10. To wring out a power shaft from a transmission flange.
  11. On models from ABS a few to delay back the sensor of number of turns.
  12. For shaft removal respectively to turn out a steering.
  13. Installation: to establish on the internal hinge new sealing laying. For this purpose to remove from laying a protective film.
  14. At first to insert a shaft from a wheel. Then crosswisely to tighten fixing bolts on a drive flange from a transmission (bolts М8: 45 N • m; bolts М10: 80 N • м). Do not forget sealing laying!
  15. To lower the car, to block wheels. New bolts of a nave of wheels to tighten as follows:
  16. Bolt М14 x 1,5: to tighten the moment of 120 N • m and in summary to tighten for 1/4 (90 °).
  17. Bolt М16 x 1,5: to tighten the moment of 200 N • m and in summary to tighten for 1/4 (90 °).
  18. To tighten nuts on on connecting draft of the stabilizer the moment of 20 N • m.
  19. On models from ABS manually to push the sensor of number of turns 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 remove a wheel cap.
  2. To weaken wheel bolts.
  3. To weaken a six-sided bolt in a wheel nave; for this purpose the car should 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 shestigrannik, fixing a shaft to differential of the back bridge.
  7. To wring out the driveshaft from a drive flange at a transmission.
  8. A few to delay back the sensor of number of turns of ABS system.
  9. To take out a shaft.
  10. Installation: to establish on the internal hinge new sealing laying. For this purpose to remove from laying a protective film.
  11. At first to insert a shaft from a wheel. Then crosswisely to tighten fixing bolts on a drive flange from the inside (bolts М8: 45 N • m; bolts М10: 80 N • м). Do not forget sealing laying!
  12. To lower the car, to block wheels. A new bolt of a nave of a wheel to tighten as follows:
  13. Bolt М14 x 1,5: to tighten the moment of 120 N • m and in summary to tighten for 1/4 (90 °).
  14. Bolt М16 x 1,5: to tighten the moment of 200 N • m and in summary to tighten for 1/4 (90 °).
  15. To tighten nuts on on connecting draft of the stabilizer the moment of 20 N • m.
  16. Manually to push the sensor of number of turns of ABS system against the stop.

 Help: do not move cars with the removed driveshaft; otherwise the bearing of a nave of a wheel is damaged. At an emergency situation it is necessary to establish only the external hinge.

On Audi cars various power shafts depending on engine and transmission type are established. Therefore upon purchase of spare parts have at itself 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–rasporny washer;
3–tarelchaty 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 an 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 a leading shaft.
  6. To establish a tarelchaty spring and a rasporny washer in case they were established in the corresponding version of a power shaft as it is shown in drawing. Do not forget rubber cuffs.
  7. At installation to get the hinge on a shaft by means of a plastic hammer until the lock ring will be fixed.
  8. To grease the hinge: on the new hinge with external diameter of 81 or 88 mm 90 g of plastic MoS2 greasing (VW G 6), thus 40 g in the hinge and 50 g in a cuff are necessary.
  9. On hinges with external diameter of 98 mm the bigger amount of greasing is necessary: 120 g of plastic MoS2 greasing (VW G 6), thus 80 g in the hinge and 40 g in a cuff.
  10. If already used hinges are established, in them it is necessary to add greasings only.
  11. Strong to compress 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 patiently 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 a 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 tarelchaty spring, before installation it is necessary to put on a spring a shaft or to check its situation: on external edge it should be camber towards the hinge.
  7. To put on the hinge a semi-axis, to establish a lock ring.
  8. The lock ring in itself will not get to a groove, therefore it is necessary to clamp a semi-axis in a vice, to establish a big replaceable face head or a piece of a pipe over an internal part of the hinge and sharply to strike on it with a hammer. The hinge will a little move back, bending a spring, and the lock ring will enter into a groove.
  9. Grease the hinge: on the new hinge with external diameter of 90 or 100 mm 90 g of plastic MoS2 greasing (VW G 6), thus 40 g in the hinge and 50 g in a cuff are necessary.
  10. On hinges with external diameter of 108 mm the bigger amount of greasing is necessary: 120 g of plastic MoS2 greasing (VW G 6), thus 35 g in the hinge and 85 g in a cuff.
  11. If already used kardanny hinges are established, in them it is necessary to add greasings only.
  12. Before hinge screwing up (or a cuff flange) put on a sealing surface between a flange of a cuff and the hinge condensing means of VW D 3.

Removal of the internal hinge

Tripod hinge

The Kardanny Tripod hinge (1) cannot be separated from a leading semi-axis. 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 semi-axis and a protective cuff. Thus, at replacement 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, 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 konsistentny greasing 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 konsistentny G 000 605 greasing. At replacement of a cuff it is necessary to add only a little greasing.