Audi Workshop Service and Repair Manuals

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

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	Hexagon key -V.A.G 1669-

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

t	-1-Two-arm puller -Kukko 20/10- with hook -Matra V170-

t	Stud M8x100 mm

Dismantling –  Secure gearbox to assembly stand. –  Turn gearbox on assembly stand with oil drain plug downwards. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove oil drain plug and allow gear oil to drain off. –  If drive flange cap is fitted, pierce a hole in centre of cap using a screwdriver and lever out cap.

–  Unscrew bolt for flange shaft (right-side)/output shaft with drive flange using hexagon key -V.A.G 1669- (counterhold with drift to prevent shaft from turning).   Note The flange shaft (right-side)/output shaft with drive flange remains in the bevel box. –  Unscrew bolts securing bevel box to manual gearbox -arrows A- and -arrow B-. –  Detach bevel box from manual gearbox and remove bevel box. –  Remove clutch release lever and release bearing → Chapter. –  Unbolt guide sleeve → Chapter.

–  Unbolt cover -arrow- from gearbox housing.

–  Remove selector fork for 5th gear -arrows-.   Note Before lifting the locking collar, take off spring and locking pieces. Then replace locking collar on synchronising hub again, but without selector fork.

–  Remove bolts -A- for synchronising hub and 5th gear wheel, to do this select 1st gear -arrows 2 and 3- and 5th gear -arrow 1-.

–  Pull off synchronising hub with selector gear for 5th gear and remove needle bearing. A -  Two-arm puller -Kukko 20/10- with hooks -Matra V170- B -  Hexagon bolt M10x20

–  Assemble two-arm puller -Kukko 20/10- with hooks -Matra V170--item A- and align centrally by turning screw -arrow- to pull off 5th gear wheel. B -  Hexagon bolt M10x20 –  Pull off gear wheel using two-arm puller; if necessary, heat gear wheel using hot air blower -V.A.G 1416- prior to pulling off.   Note t  When pulling off the gear wheel ensure that the hooks do not bend outwards, if necessary tighten screw -arrow-. t  Check 5th gear wheel for damage after pulling off.

–  Unscrew countersunk bolt -arrow- for flange shaft (left-side) (counterhold flange shaft with drift to prevent it from turning).

–  Remove bolts -arrows- for reverse shaft support.

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

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

–  Remove pivot pins -A- from top of gearbox. –  Remove bolts -B- connecting gearbox housing to clutch housing near differential.

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

–  Take off gearbox housing.   Note If necessary, use a lever to carefully lift the gearbox housing all round and alternating between sides at the protruding flange -arrows-, taking care not to damage sealing surfaces.

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

–  Remove nuts -B- for output shaft bearing mounting.   Note Bolts -A- were removed at an earlier stage.

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

Assembling –  Install differential. –  Renew seals -arrows- for output shaft bearing mounting.   Note The illustration only shows 3 of the 4 seals. –  Install input shaft, output shaft and reverse shaft together. –  Tighten nuts for output shaft bearing mounting to 25 Nm and then turn 90° further.

–  Remove locking fluid on thread in reverse shaft support -arrow- using thread tap or similar. –  Fit reverse shaft support.

–  Install selector mechanism for reverse gear. l  Installation position: reverse gear. –  Install selector forks together with gear selector plates.

–  Fit stud M8x100 mm -item A- into reverse shaft support so that support is aligned when gearbox housing is fitted. –  Align gear selector plates. l  The detent segments must be positioned in the grooves on the locking collars. –  Put gearbox housing in position.

–  Install reverse shaft support -arrow- as follows: 1.  Screw in bolt -a- hand-tight. 2.  Then unscrew stud M8x100 mm fitted some steps earlier. 3.  Screw in bolt -b- hand-tight. 4.  Tighten bolt -a- to 30 Nm. 5.  Tighten bolt -b- to 30 Nm.

–  Install pivot pin -arrow- for selector forks; to do this align selector mechanism using a screwdriver so that the relevant pivot pin can be inserted. –  Install cover plate for selector shaft.

Install selector shaft as follows: –  Move gear selector plates to neutral. –  Engage the lug -arrow 1- into the cut-out on the gearbox housing. Position selector shaft so that selector finger -arrow 2- is engaged in selector plates. –  Install selector mechanism cover for selector shaft.

–  Fit 5th gear wheel. l  Installation position: the groove running round the gear wheel -arrow- faces to the gearbox housing.

–  Drive on 5th gear wheel.

Checking 5th gear synchro-ring for wear: –  Press 5th gear synchro-ring against tapered seat on selector gear and measure gap -a- using a feeler gauge. l  Specified gap: 1.1 ... 1.7 mm. l  Wear limit 0.5 mm. –  Install 5th speed selector gear with needle bearing. –  Fit 5th gear synchro-ring on selector gear. –  Assemble 5th gear synchronising hub/locking collar before installing → Fig..

Installation position of 5th gear synchronising hub/locking collar l  The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchronising hub -arrow 2- face the gearbox housing. l  Retainers in synchronising hub -arrow 3- align with cast locking pieces on 5th gear synchro-ring.

5th gear synchro-ring with cast locking pieces -arrows-.

–  Drive on 5th gear synchronising hub.   Note When driving on, ensure clearance for synchro-ring.

–  Fit securing bolts for 5th gear synchronising hub and gear wheel. Installation position of dished springs for securing bolts for 5th gear wheel and synchronising hub: l  The outer diameter (concave side -arrows-) faces 5th gear.

–  Tighten bolts -A- for synchronising hub and 5th gear wheel, to do this select 1st gear -arrows 2 and 3- and 5th gear -arrow 1-. –  Install selector fork for 5th gear.

Adjust 5th gear as follows: –  Engage 5th gear. –  Slacken bolt -1-. –  Press locking collar and selector jaw in direction of -arrow- and tighten bolt -1- to 25 Nm. l  Check adjustment: It should not be possible to slide a 0.2 mm feeler gauge between locking collar and selector gear. –  Repeat adjustment if necessary. –  Disengage 5th gear. l  The locking collar should now be in neutral position and the synchro-ring should move freely. –  Secure gearbox housing cover. –  Install complete flange shaft (left-side) → Item. –  Install guide sleeve for release bearing → Chapter. –  Install clutch release lever and release bearing → Chapter.   Note

Always renew O-ring between bevel box and gearbox -arrow A- and seals on oil supply drillings -arrow B- and -arrow C-. Lightly oil O-ring and seals before installing. –  Push bevel box completely onto gearbox, at the same time ensuring that the bevel box input shaft splines are guided centrally onto the differential connecting piece. l  If the splines are correctly positioned and the components are located centrally, the bevel box will slide against the gearbox onto the stop.   Note Do not use the securing bolts to pull the bevel box onto the gearbox. This could cause the bevel box to tilt and the securing eyes may break off.

–  Tighten bolts securing bevel box to manual gearbox -arrows A- and -arrow B-. –  Tighten bolt for flange shaft (right-side) or drive flange with output shaft using hexagon key -V.A.G 1669- (counterhold flange shaft with drift to prevent it from turning). –  Renew drive flange cap, if fitted.