Audi Workshop Service and Repair Manuals

Servicing gearbox housing

Special tools and workshop equipment required

t	Drift sleeve -VW 244B-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Tube -VW 416 B-

t	-1-Internal puller -Kukko 21/2-

t	-1-Internal puller -Kukko 21/4-

t	-4-Counter-support -Kukko 22/2-

t	Guide pin -VW 436A-

t	Guide pin -VW 439-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Guide pin -10-15-

t	Thrust piece -3124-

t	Punch -3264-

t	Assembly tool -3290-

t	Torque wrench -V.A.G 1331-

t	Drift -T10168-

t	Thrust piece -T10203-

t	Drift -T10169-

t	Or drift -T10362- → Fig.

t  -1-Internal puller -Kukko 21/2- t  -1-Internal puller -Kukko 21/4- t  -4-Counter-support -Kukko 22/2-

1 -	Gearbox housing

q	If renewed: Adjust output shafts and differential → Chapter

q	Modifications in area of mounting for grooved ball bearing on input shaft → Item

q	Select correct components from → Electronic parts catalogue

2 -	Sealing cap

q	Removing → Fig.

q	Driving in → Fig.

3 -	Oil drain plug

q	Tightening torque → Fig.

4 -

Seal

q	If fitted, always renew

5 -	Oil filler plug

q	Tightening torque → Fig.

6 -	Angled rod

q	For adjusting selector mechanism → Chapter

q	Can be renewed without dismantling gearbox

q	Removing → Fig.

q	Installation position → Fig.

q	Driving in → Fig.

7 -	Bearing bush

q	For selector shafts

q	Pulling out → Fig.

q	Driving in → Fig.

8 -	Stop sleeve

q	Pressing out (gearbox dismantled) → Fig.

q	Driving out (gearbox not dismantled) → Fig.

q	Identification of different types of stop sleeve → Fig.

q	Driving in stop sleeve with shoulder → Fig.

q	Driving in stop sleeve without shoulder → Fig.

9 -	Needle bearing

q	For reverse shaft

q	Always renew after removing

q	Pulling out → Fig.

q	Pressing in → Fig.

10 -	Tapered roller bearing outer race

q	For 5th/6th and reverse gear output shaft

q	Removing and installing → Chapter

q	If renewed: Adjust 5th/6th and reverse gear output shaft → Chapter

11 -

Shim

q	For 5th/6th and reverse gear output shaft

q	Table of adjustments → Chapter

12 -	Tapered roller bearing outer race

q	For 1st - 4th gear output shaft

q	Removing and installing → Chapter

q	If renewed: Adjust 1st - 4th gear output shaft → Chapter

13 -

Shim

q	For 1st - 4th gear output shaft

q	Table of adjustments → Chapter

14 -	Tapered roller bearing outer race

q	For differential

q	Removing and installing → Chapter

q	If renewed: adjust differential → Chapter

15 -

Shim

q	For differential

q	Table of adjustments → Chapter

16 -	Bearing bush

q	For selector shaft

q	Pulling out → Fig.

q	Driving in → Fig.

17 -	Sealing plug

q	Driving out → Fig.

q	Driving in → Fig.

18 -

Seal

q	Renewing → Chapter

Removing sealing cap -A- –  Pierce rubber in centre of sealing cap with a screwdriver -B- and pry off sealing cap -in direction of arrow-.

Driving in sealing cap onto stop

Removing angled rod for selector shaft –  Shear off rod in released position. –  Insert screwdriver -A- in bore for angled rod -B-. –  Lever out angled rod in direction of -arrow-.

Installation position of angled rod –  Marking on angled rod -arrow- must face towards connection on slave cylinder -1-. Dimension -a- must be approx. 45°.

Driving in angled rod -arrow- for selector shaft as far as tool stop   Note Angled rod must be in released position when driving in.

Pulling out bearing bush for selector rod A -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2- B -  Counter-support, e.g. -Kukko 22/2-

Driving in bearing bush for selector rod (drive in until tool contacts stop)

Pressing stop sleeve -A- out of gearbox housing –  Place gearbox housing on thrust plates -VW 401- and -VW 402- so that the dowel sleeves in the gearbox housing do not become damaged.

Driving out stop sleeve (gearbox not dismantled) using guide pin -10-15- l  Locking bolt and selector shaft removed –  Turn gearbox so that stop sleeve does not drop into gearbox.

Identification of different types of stop sleeve The following stop sleeves can be installed: Stop sleeve with shoulder -arrow 1- → Fig. Stop sleeve without shoulder -arrow 2- → Fig. Select correct components from → Electronic parts catalogue.

Driving in stop sleeve with shoulder as far as tool stop l  Gearbox housing bolted to clutch housing

Driving in stop sleeve without shoulder as far as tool stop l  Gearbox housing bolted to clutch housing

Pulling needle bearing for reverse shaft out of gearbox housing A -  Internal puller 23.5 ... 30 mm, e.g. -Kukko 21/4- B -  Counter-support, e.g. -Kukko 22/2-   Note The needle bearing is destroyed during removal and must be renewed.

Pressing needle bearing -A- into gearbox housing –  Before pressing in, place reverse shaft thrust washer -A- onto needle bearing. –  Support gearbox housing with tube -VW 416 B- directly below bearing mounting.

Pulling out selector shaft bush –  Hold spindle of assembly tool -3290- tight and turn nut -B-. A -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2-

Driving in bearing bush -A- for selector shaft until flush

Driving out sealing plug -1- –  Drive out plug -1- from inside of gearbox housing -arrow-.

Driving in sealing plug -1- –  Use punch -3264- to drive in sealing plug to dimension -a- = approx. 3 mm below top edge of housing.