Audi Workshop Service and Repair Manuals

Dismantling and assembling gearbox housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks

Special tools and workshop equipment required

t	Thrust plate -40 - 105-

t	Tube -VW 420-

t	Tube -VW 519-

t	Oil seal extractor lever -VW 681-

t	Multi-purpose tool -VW 771- with -VW 771/38- and -VW 771/40-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Extension -30 - 23-

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

t	Torque wrench -V.A.G 1331-

t	Hexagon key -V.A.G 1669-

t	Pressing-out tool -2054-

t	Counterhold tool -3435-

t  -2-Puller-Kukko 18/1-

t  -1- Two-arm puller -Kukko 20/10-

t  -1- Ball bearing extractor -Matra V/146.6- t  -2- Hook -Matra V/146.7- t  -3- Support ring -Matra 6305- t  Puller arm -Matra V/170- t  Protective gloves Dismantling l  Gearbox secured to engine and gearbox support → Chapter. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Turn the gearbox in the engine and gearbox support so that the oil drain plug is facing downwards. –  Drain off gear oil.

–  Detach the clutch release lever -A- with release bearing -B-. –  Unscrew the guide sleeve -C-.

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

–  Unbolt gearbox housing cover and detach together with gasket. –  Screw the selector finger to the selector shaft. –  Engage 5th gear -arrows 1 and 2-.

–  Unfasten the lock nut -arrow A- beneath the 5th gear selector fork. –  Unscrew ball stud -arrow B- and remove selector fork together with 5th gear locking collar.

–  Push 5th gear locking collar over synchronising hub again. –  Unscrew the bolt -A- for the 5th gear wheel. To do so, engage 5th gear -arrow 1- and 2nd gear -arrow 2, 3-. l  After engaging both gears the input shaft and output shaft are locked; the synchronising hub and gear wheel cannot turn. The bolt can now be loosened. –  Detach the 5th gear locking collar and disengage 2nd gear.

–  Detach circlip -arrow- for synchronising hub.

–  Detach synchronising hub with 5th speed selector gear. A -  Two-arm puller -Kukko 20/10- with puller arm -Matra V/170-

–  Detach the needle bearing -arrow-.

–  Detach the 5th gear wheel. To do so, position the support ring -Matra 6305--Item 3- on the gear wheel such that the chamfer is facing upwards. –  Insert the ball bearing extractor -Matra V/146.6--Item 1- with 3 hooks -Matra V/146.7--Item 2- in the gear wheel recesses. –  Press down the support ring -Matra 6305- and tension the hooks -Matra V/146.7- with the nut -arrow-.

–  Squeeze and detach the clip -arrow-. –  Remove the clutch housing bolts and detach the clutch housing. –  Detach the differential from the gearbox housing.

–  Use the multi-purpose tool -VW 771- and -VW 771/38- to pull out the sealing plug.

–  Pull out the shift shaft (drive out with a mandrel if necessary).

–  Remove the spring -arrow- between the selector finger -A- and shift console -B-. –  Take out the selector finger.

–  Remove the bolt -arrow- and take out the shift console with bushing.

–  Unscrew reversing light switch -F4--item 1- and bolts -2, 3, 4- for reverse gear.

–  Remove the 5th gear selector rod -1- and the selector rod -2- for reverse gear with reverse lever -3-.

–  Detach the gearbox from the engine and gearbox support to press out the output shaft. –  Press the output shaft -A- out of the mount in the gearbox housing. –  Re-attach the gearbox to the engine and gearbox support.

–  Drive out reverse gear shaft -1-. –  Take the input shaft -5-, output shaft -4-, 1st and 2nd gear selector rod -Item 3-, 3rd and 4th gear selector rod -Item 6-, reverse gear wheel -2- and shaft -1- out of the gearbox housing.

Assembling l  Tightening torques → Chapter –  Press the taper roller bearing outer race for the output shaft into the gearbox housing → Chapter. –  Insert the output shaft -3- with 1st and 2nd gear selector rod -Item 4-. –  Slide the reverse gear wheel -1- over the shaft -2- and insert the shaft.

–  Lift the reverse gear wheel with the pressing-out lever -VW 681- to permit subsequent insertion of the reverse lever for the reverse gear.

–  Lift the output shaft -1- with 1st and 2nd gear selector rod -Item 2- slightly and re-insert together with the drive shaft -3- and the 3rd and 4th gear selector rod -Item 4-.   Note t  Reverse gear wheel still raised with pressing-off lever -VW 681-. t  On insertion with 3rd and 4th gear, guide the input shaft past the 4th gear wheel of the output shaft.

–  Secure reverse gear shaft -arrow-.

–  Insert the reverse lever -1- in the selector rod -2- for reverse gear. –  Install components; for this purpose, first insert reverse lever into reverse gear wheel.

–  Secure the reverse lever -arrow-. –  Take the pressing-out lever -VW 681- out of the gearbox housing.

–  Fit and secure the 5th gear selector rod -Item 1-.

–  Move the selector rods -A- into neutral position. –  Fit the shift console -B- with bushing and bolt. –  Align the shift console. To do so, insert the shift shaft -C- and tighten the bolt -arrow-. –  Take the shift shaft out again.

–  Insert the selector finger -1- in the shift console -2-.

–  Insert the spring -arrow- between the selector finger -1- and shift console -2-. –  Press the shift shaft -3- into the selector finger and shift console. l  Installation position: shoulder facing into gearbox housing –  Drive in the sealing plug -4- such that it is flush. –  Adjust the selector finger and selector sleeve if necessary → Chapter. –  Insert differential. –  Install clutch housing. –  Screw in the reversing light switch -F4-. –  Fit the springs, thrust washers, tapered rings and flange shafts.

–  Pay attention to the distinguishing features of the flange shafts → Fig..

–  Drive on 5th gear wheel. l  Installation position: shoulder on inside diameter faces gearbox housing

–  Screw in a new bolt -1- with dished washer -2- for the 5th gear wheel. l  Installation position of dished spring: outer diameter (concave side) faces 5th gear. –  Fit thrust washer -3- for 5th speed selector gear. l  Installation position of thrust washer: Shoulder on inside diameter faces towards tapered roller bearing.

WARNING Wear protective gloves. –  Heat the sleeve for the 5th gear needle bearing to approx. 100 °C on a hot plate and drive on. –  Fit 5th speed selector gear -item 1- with needle bearing. –  Position 5th gear synchro-ring -item 2- on selector gear. l  The drivers -arrow- of the 5th gear synchro-ring face the synchro-hub.

–  Fit the 5th gear synchro-hub. l  Installation position: Tall collar -a- of synchronising hub facing gearbox housing.

–  Drive on the 5th gear synchro-hub -Item 1- with the attachment -30 - 23-.   Note t  Pay attention to freedom of movement of the synchro-ring when driving on the synchro-hub. t  The locking pieces -arrow- must be positioned in the recesses of the synchro-ring. –  Determine new circlip -2-. –  Determine and fit the thickest circlip which can still just be inserted; part no. → Electronic parts catalogue.

Available circlips - Thickness of circlips in mm
2.0	2.3	2.6
2.1	2.4
2.2	2.5

–  Then fit the clip -3-.

–  To do so, squeeze the clip -arrow- and position it on the 5th gear selector rod.

–  Insert the 5th gear locking collar. l  Installation position: teeth with pointed end -arrow A- facing 5th speed selector gear –  Insert the markers on the splines -arrow B- in the recesses at the synchro-hub.

–  Tighten the bolt -A- for the 5th gear wheel. To do so, engage 5th gear -arrow 1- and 2nd gear -arrow 2, 3-. –  Detach the locking collar again.

–  If necessary, use a tap M8x1 to clean the tapped hole for the ball stud in the housing. –  Install locking collar together with 5th gear selector fork. –  Screw back the lock nut -arrow A- beneath the 5th gear selector fork. –  Screw in the ball stud -arrow B-.

Setting 5th gear - basic adjustment: –  Coat the thread of the ball stud with locking compound -D 000 600-. –  Turn gearbox to installation position. l  All selector rods must be in neutral position. –  Loosen lock nut on ball stud. –  By turning the ball stud -arrow-, set the locking collar flush with the synchro-hub.

Fine adjustment: –  Select 5th gear. –  Screw in the ball stud -arrow A- until there is no longer any axial clearance at the 5th gear selector fork in the groove of the locking collar. –  Then screw back the ball stud until there is still just clearance between the locking collar and selector fork (roughly 1/8 of a turn). –  Lock the ball stud with the lock nut -arrow B- under the 5th gear selector fork against the gearbox housing (the stud must not be turned). –  Disengage 5th gear. l  Locking collar should now be in the neutral position. l  The synchro-ring must move freely. –  Fit gasket. –  Install gearbox housing cover.