Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 401 Thrust plate
• ◆ VW 402 Thrust plate
• ◆ VW 407 Press tool
• ◆ VW 408 A Press tool
• ◆ VW 412 Press tool
• ◆ VW 416 B Tube

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 353 Gearbox support
• ◆ VW 433 Press piece
• ◆ VW 454 Press piece
• ◆ VW 457 Support rails
• ◆ VW 801 Holding plate

Special tools and workshop equipment required

• ◆ 40-105 Thrust plate
• ◆ 41-501 Drift sleeve
• ◆ 2040 Tube
• ◆ 2050 Thrust piece
• ◆ 3074 Press disc
• ◆ 3161 Extension

Special tools and workshop equipment required

• ◆ 3235 Press
• ◆ V.A.G 1582 Taper roller bearing puller
• ◆ V.A.G 1582/7 Grip
• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 3 - Kukko 17/2 Separating device
• ◆ 4 - Kukko 22/2 Counter support

Notes:

• ◆ When installing new gear wheels, consult technical data
  .
• ◆ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview

• Gearbox housing
• Shim
• ◆ Determining thickness => Page 35-14
• Taper roller bearing outer race
• ◆ Pulling out => Fig. 1
• ◆ Pressing in => Fig.2
• Circlip
• ◆ Redetermine if taper roller bearing -item -5- or input shaft -item 8- are replaced =>Fig.11

• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.10
• 5th gear wheel
• ◆ Pressing off => Fig. 4
• ◆ Pressing on => Fig.9
• 3rd, 4th and 6th gear wheel
• ◆ Pressing off => Fig. 5
• ◆ Pressing on => Fig.7
• Input shaft
• ◆ Adjusting => Page 35-14
• Taper roller bearing inner race
• ◆ Pressing off => Fig.6
• ◆ Pressing on => Fig. 8
• Taper roller bearing outer race
• ◆ Pulling out => Fig.12
• ◆ Pressing in => Fig.13
• Clutch housing

→ Fig.1    Pressing taper roller bearing outer race out of gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.2    Pressing taper roller bearing outer race into gearbox housing

• ‒ Support gearbox housing with press piece 3062 directly below bearing support.

→ Fig.3    Pulling off taper roller bearing inner race

A - Vice clamps/vice

• ‒ Before setting up pulling device, set extension 3161 and thrust plate 40-105 on input shaft.

→ Fig.4    Pressing off 5th gear wheel

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.5    Pressing off 3rd, 4th and 6th gear wheel

→ Fig.6    Pressing off taper roller bearing inner race

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.7    Pressing on 3rd, 4th and 6th gear wheel

• ‒ Heat gear wheel to about 100 °C
• ‒ Press on gear wheel quickly so that the heat is not immediately transferred to input shaft.

→ Fig.8    Pressing on taper roller bearing inner race

→ Fig.9    Pressing on 5th gear wheel

→ Fig.10    Pressing on taper roller bearing inner race

→ Fig.11    Determining thickness of circlip

• ‒ Determine the thickest circlip which will just fit and install it.

The following securing clips are available:

→ Fig.12    Pulling taper roller bearing outer race out of gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.13    Pressing in taper roller bearing outer race