Audi Workshop Service and Repair Manuals

Installing l  A new grooved ball bearing has been pressed onto the input shaft → Item

–  Insert input shaft -1-, output shaft for 5th and 6th gear -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.

–  Then install differential -1-.   Note A second mechanic is required for installing the shafts in the clutch housing. –  Take 1st - 4th gear output shaft -3- with selector rods -4- in your right hand as illustrated. –  Lift differential slightly with your left hand. –  At the same time, have the second mechanic lift the input shaft and output shaft for 5th, 6th and reverse gear -2- slightly, together with the reverse shaft. –  Now insert 1st - 4th gear output shaft in direction of -arrow-. The teeth of the input shaft, output shafts and final drive gear/differential must mesh. –  Now, together with second mechanic, locate shafts and differential in their bearing seats.

–  Secure support bridge -30-211A- for input shaft to clutch housing.   Note Illustration shows clutch housing turned through 180° for clarity. –  Screw in bolt -A- until input shaft lifts slightly. From gearbox manufacturing date 10 04 6 to 20 01 8: A shim is fitted on either side of grooved ball bearing for input shaft → Item.

Shim (top)	Outside diameter	78.6 mm
Shim (bottom)	Outside diameter	85 mm

Measuring area above seat for grooved ball bearing

Area above grooved ball bearing	Dimension „a“	Shim (top)
Up to gearbox manufacturing date 09 04 6	10 mm	No
From gearbox manufacturing date 10 04 6 onwards	10.7 mm	Yes

In the gearbox housing, the area below the seat for the grooved ball bearing has also been modified -arrow-

Area below bearing seat		Shim (bottom)
Up to gearbox manufacturing date 09 04 6	Not modified	No
From gearbox manufacturing date 10 04 6 onwards	Slightly deeper	Yes

–  If necessary, fit a shim (outer diameter = 85 mm) -1- onto grooved ball bearing -2-. –  Using hot air blower, e.g. -V.A.G 1416-, heat area around seat of grooved ball bearing for input shaft in gearbox housing for approx. 10 minutes to 100 °C.

–  Fit gearbox housing and tighten new bolts -A-, -B- and -C- to specified torque. Allocation of bolts: A -  Bolt with captive washer B -  Bolt without washer C -  Bolt with captive washer

–  If a shim was fitted on the grooved ball bearing before installing the gearbox housing, a shim -1- (outer diameter = 78.6 mm) must also be fitted after installing the gearbox housing -2- → Anchor.

–  Install circlip -1- for input shaft grooved ball bearing. –  Remove support bridge -30 -211A- for input shaft. –  If stop sleeve for selector shaft has been removed, drive it in now → Fig. (drive in until tool reaches stop). –  Turn gearbox on assembly stand so that opening for selector shaft faces up.

–  Insert selector shaft -1- into bottom mounting -2- and into selector forks -3-.   Note The sealing cap is removed to give a better illustration.

–  Now push selector shaft -1- against stop sleeve -2- in direction of -arrow- and run selector finger -3- down through selector forks and onto stop. l  Selector mechanism cover -4- should be parallel to joint surface on gearbox housing. l  Selector shaft should move up and down easily (gate selector movement).   Note If the selector mechanism cover is not parallel with the joint surface, the selector shaft is not seated in its bottom mounting.

–  Tighten bolts -3- for selector mechanism cover -4-. –  Screw in locking bolt -2-; angled rod -arrow- must be released. –  Install reversing light switch -F4--1-. –  Install both flange shafts with springs, thrust washers and tapered rings.

–  Drive in input shaft oil seal. –  Install slave cylinder with release bearing → Chapter. –  Select all gears.

–  Drive sealing cap into gearbox housing onto stop.