Audi Workshop Service and Repair Manuals

Assembly sequence - dismantling and assembling complete gearbox

Removing and installing cover for gearbox housing, clutch housing, selector shaft with selector mechanism cover, input shaft, output shaft, differential and selector mechanism

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Drift -VW 295-

t	Drift sleeve -VW 244 B-

t	Hot air blower -V.A.G 1416-

t	Torque wrench -V.A.G 1331-

t	Stud M8 x 100 mm

t	Support bridge -30-211A-

t	Thrust piece -32 - 111-

t	Thrust piece of assembly tool -T10030/4-

t	Tube -VW 416 B-

t	Puller plate -T10408-

t	Spacers -T10408/1-

t	Thrust blocks -T10408/2-

t	Brackets -T10408/3-

t	Support bridge -T10323-

t	Assembly tool -3253/7-

t	Press tool -VW 433-

t	Torque wrench -V.A.G 1332-

Special tools and workshop equipment required t

Hexagon bolts M7 x 35 with washers Puller -2- -Kukko 18/1- Removing –  Remove clutch release lever, release bearing and guide sleeve → Chapter. l  The bearings of the input shaft and output shaft must not be damaged when removing and installing 5th gear.

l  For this reason, when attaching the gearbox to gearbox support -VW 353-, you must first attach the following tools to provide the necessary support: Below input shaft: t  Support bridge -30-211A- t  Thrust piece -32 - 111- t  Thrust piece -T10030/4- –  Secure bolt of support bridge -30-211A- with lock nut -A-. Below bearing mounting for output shaft: t  Support bridge -T10323- t  Assembly tool -3253/7- t  Press tool -VW 433-

–  Securing gearbox on gearbox support -VW 353- –  Place drip tray -V.A.G 1306- underneath. –  Unscrew oil filler plug and oil drain plug. –  Drain off gear oil.

–  Unbolt gearbox housing cover -arrow-.

Remove 5th gear selector fork as follows: –  Cover over openings with a cloth. –  Move selector fork -1- to neutral. –  Then remove both bolts -2- for pivot pins. –  Pull out pivot pins in direction of -arrows A-. –  Take out selector fork in direction of -arrow B-.

–  Remove bolts -A- for synchro-hub and 5th gear wheel, to do this select 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  After engaging both gears the input shaft and output shaft are locked; the synchro-hub and gear wheel cannot turn. The two bolts can now be loosened.   Note If the shafts are not being renewed, carefully clean residual locking compound out of tapped holes using a thread tap.

–  Remove both bolts -arrows- for reverse shaft support.

–  Gearbox for vehicles with start/stop system: remove gearbox neutral position sender -G701--arrow-.

–  Remove selector shaft with selector mechanism cover. To do this, set selector shaft in neutral position. Then remove bolts -arrows- and pull selector shaft out of gearbox housing.

–  Remove cover plate -A- and pivot pins -B- from underside of gearbox.

–  Remove pivot pins -A- on top side of gearbox and bolts -B- securing gearbox housing to clutch housing (near differential).

–  Remove bolts -A- securing gearbox housing from inside clutch housing.   Note Do not remove nuts -B- for output shaft bearing mounting.

–  Remove both flange shafts. –  Take out flange shafts together with springs, thrust washers and tapered rings.

Pull off the following components, together with the gearbox housing: t  5th gear synchro-hub t  5th gear wheel l  You must secure the two brackets -T10408/3- to the 5th gear wheel. l  Always position the brackets above 2 opposite ribs on the housing -arrows-.   Note t  A needle bearing is located underneath the 5th gear wheel. t  Please secure the two brackets. This will prevent the needle bearing from coming into contact with the 5th gear wheel when the gearbox housing is pulled off.

Use puller plate -T10408- together with the following special tools: t  Spacers -T10408/1- t  Thrust blocks -T10408/2- t  Brackets -T10408/3- t  Puller Kukko 18/2 –  Screw the 5 spacers -T10408/1- into threaded holes for gearbox housing cover. –  Bolt puller plate -T10408- onto spacers -T10408/1-. A -  Hexagon bolts M7 x 35 with washers l  Tightening torque: 18 Nm

–  Fit thrust blocks -T10408/2- on shafts. –  Attach pullers Kukko 18/1. –  Pull off 5th gear synchro-hub, 5th gear wheel and gearbox housing by tightening spindles -A- alternately (about 1 2 turn at a time). –  If necessary, heat 5th gear wheel using hot air blower -V.A.G 1416- before pulling off.

–  Remove selector forks -A- together with selector plates. –  Unscrew bolt for reverse gear selector mechanism -B-.

–  Remove nuts -B- for output shaft bearing mounting.

–  Remove reverse gear -A-, input shaft-B- and output shaft -C- one after the other from clutch housing. –  Take out differential.