Audi Workshop Service and Repair Manuals

Servicing gearbox housing and selector shaft

Special tools and workshop equipment required

t	Crown wheel adjusting tool -VW 521-

t	Fitting tool -3128-

t	Installing tool -40-503-

t	Mandrel -30-505-

t	Drift -VW 295-

t	Adapter -VW 295 A-

t  Spindle from assembly tool -3291-

t  -1-Internal puller -Kukko 21/3- t  -4-Counter-support -Kukko 22/1-

1 -	Gearbox housing

q	If renewed: adjust differential → Chapter

q	From gearbox build date 03 08 8 onwards: with additional threaded hole for reversing light switch -F4- → Fig.

2 -	Dowel sleeve

q

2x

3 -

Sleeve

q	Remove using pliers

q	Drive in onto stop

4 -

Cap

q	For gearbox breather

5 -	Selector shaft

q	Removing → Fig.

6 -

Stop cap

7 -

Spring

8 -	Retaining plate

q	Hold retaining plate when releasing circlip → Item. Then carefully release spring → Item.

9 -

Circlip

q

Renew

10 -	Needle bearing

q	For output shaft

q	Removing → Fig.

q	Installing → Fig.

11 -	Reversing light switch -F4-

q

23 Nm

q	Fitted from gearbox build date 03 08 8 onwards

12 -	Locking bolt

q

40 Nm

q	For selector shaft

q	Fitted from gearbox build date 03 08 8 onwards

q	Apply sealant -AMV 188 200 03- when installing

13 -	Tapered roller bearing outer race

q	For differential

q	Removing and installing → Chapter

q	If renewed: adjust differential → Chapter

14 -

Shim “S1”

q	Table of adjustments → Chapter

15 -	Reversing light switch -F4- and locking bolt for selector shaft

q

23 Nm

q	Fitted up to gearbox build date 02 08 8

q	From gearbox build date 03 08 8, reversing light switch -F4- and locking bolt are supplied as two separate components → Fig.

q	Apply sealant -AMV 188 200 03- when installing

16 -

Oil seal

q	For flange shaft

q	Renewing → Chapter

17 -	Ball sleeve

q	For selector shaft

q	Pulling out → Fig.

q	Drawing in → Fig.

18 -

Oil seal

q	For selector shaft

q	Can be renewed with gearbox in vehicle

q	Removing → Fig.

q	Drawing in → Fig.

Removing selector shaft –  Unscrew selector shaft sealing cap and remove together with spring. –  Set selector shaft to neutral and pull out of gearbox housing.

Removing selector shaft oil seal –  Lever out in direction of -arrow- with a screwdriver.

Pulling in selector shaft oil seal –  Pull in as far as stop. –  When gearbox is removed, drive in with -VW 521/8-.

Pulling out selector shaft ball sleeve A -  Internal puller 18.5 ... 23.5 mm, e.g. -Kukko 21/3- B -  Counter-support, e.g. -Kukko 22/1-

Pulling in selector shaft ball sleeve –  Pull in onto stop -arrow 1-. Installation position: The ball sleeve projects out of the hole at the seal end -arrow 2-.

Driving out needle bearing

Driving in needle bearing onto stop