Audi Workshop Service and Repair Manuals

Assembly sequence - gearbox without circlip for input shaft sealing cap Removing and installing gearbox housing, selector mechanism, input shaft, output shafts, differential and selector rods   Note

Sealing cap for input shaft without circlip -A-

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Installing sleeve -VW 455-

t	Multi-purpose tool -VW 771-

t	-1- Kukko 21/01 internal puller

t	-3- Kukko 17/0 splitter

t	-4- Kukko 22/1 counter-support

t	Support bridge -30 - 211 A-

t	Thrust piece -T10042-

t	Drift -T10169-

t	Thrust piece -T40008-

t	Torque wrench -V.A.G 1331-

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

t  Oil seal extractor lever -VW 681-

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

t  Socket and extended bit -T10107 A- Removing l  Gearbox removed and mounted on assembly stand → Chapter. –  Turn gearbox on assembly stand so that oil drain plug faces downwards. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Drain off gear oil.

–  Unscrew bolt for flange shaft (right-side) using socket and extended bit -T10107 A-. –  Remove all 4 bolts -arrows- securing bevel box to gearbox (illustration only shows 3 bolts). –  Carefully push bevel box away from gearbox, making sure it does not fall down.

–  Remove clutch slave cylinder with release bearing -arrows-.

–  Make sure that the selector shaft is not locked in position by the angled rod -arrow- when carrying out the following steps. –  Put selector shaft in neutral position. –  Remove locking bolt -2-. –  Remove bolts -3-. –  Remove reversing light switch -F4--1-. –  Pull selector shaft -4- out of gearbox housing.

–  Remove bolt securing flange shaft (left-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever.

–  Remove bolts -B- securing gearbox housing from inside clutch housing.   Note One of the bolts -arrow- is outside the joint flange.

–  Lock input shaft by fitting installing sleeve -VW 455- over input shaft and against clutch housing. –  Tighten splitter-A-, e.g. -Kukko 17/0- behind splines on input shaft. l  The rear side of the splitter must be in contact with installing sleeve (zero play).

–  Pierce rubber in centre of sealing cap -C- with a screwdriver. –  Pull sealing cap out of gearbox housing. A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 8 ... 12 mm, e.g. -Kukko 21/01-

Detach circlip -C- from input shaft grooved ball bearing as follows: –  Hold one end of circlip with screwdriver-A-. –  Lever other end of circlip out of slot in ball bearing -arrow- with 2nd screwdriver -B-. –  Lever circlip out further by repositioning screwdriver-B-.

–  Where fitted, detach spacer -1- from gearbox housing -2-. –  When renewing the gearbox housing, check whether the spacer has to be re-installed → Anchor.

–  Remove bolts -A-.

–  Screw adapter VW 771/40 into threaded hole in gearbox housing. –  Using hot air blower -V.A.G 1416-, heat area around seat of input shaft ball bearing in gearbox housing for approx. 10 minutes to approx. 100°C. –  Using multi-purpose tool VW 771/1, pull gearbox housing off clutch housing -arrow-.   Note If necessary, carefully apply a lever to the protruding flanges on alternate sides of the gearbox housing, taking care not to damage the sealing surfaces.

–  If fitted, detach spacer -1- from grooved ball bearing -2-. –  When renewing the gearbox housing, check whether the spacer has to be re-installed → Anchor.

–  Remove splitter-A- and installing sleeve VW 455 from input shaft.   Note

A second mechanic is required for removing the shafts from the clutch housing. –  Lift up differential -1- with your left hand. –  With your right hand, lift 1st - 4th gear output shaft together with selector rods -2--arrow A-. –  At the same time, the second mechanic must lift the input shaft, reverse shaft and 5th/6th gear output shaft -3- out of the clutch housing together with the selector rods -arrow B-.   Note If required, the differential can be put back in the clutch housing after lifting the shafts. –  Remove oil seal for input shaft using oil seal extractor lever -VW 681-.   Note Always renew grooved ball bearing on input shaft → Item.

Installing l  A new grooved ball bearing has been pressed onto the input shaft → Item. l  Tightening torques → Chapter –  Insert input shaft -1-, output shaft for 5th and 6th gear -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.

–  Install differential -1-.   Note A second mechanic is required for installing the shafts in the clutch housing. –  Take 1st - 4th gear output shaft -3- with selector rods -4- in your right hand as illustrated. –  Lift up differential slightly with your left hand. –  At the same time the second mechanic must lift the input shaft and output shaft for 5th, 6th and reverse gear -2- slightly, together with the reverse shaft. –  Now insert 1st - 4th gear output shaft in direction of -arrow-. l  The teeth of the input shaft, output shafts and final drive gear/differential must mesh. –  Now, together with second mechanic, locate shafts and differential in their bearing seats.

–  Secure support bridge -30 - 211 A- for input shaft to clutch housing.   Note Illustration shows clutch housing turned through 180° for clarity. –  Screw in bolt -A- until input shaft lifts slightly.   Note

t  On some gearboxes, grooved ball bearing for input shaft -A- and bearing mounting -B- are flattened on one side. t  Check grooved ball bearing for input shaft and gearbox housing.

Grooved ball bearing for input shaft and gearbox housing

Without flattened sides on grooved ball bearing -A- and bearing mounting -B- → Anchor

With flattened sides on grooved ball bearing -A- and bearing mounting -B- → Fig.

From gearbox manufacturing date 10 04 6 to approx. 20 01 8: A spacer is fitted on either side of grooved ball bearing for input shaft → Item.

Top spacer	Outside diameter	78.6 mm
Bottom spacer	Outside diameter	85 mm

Measuring area above seat for grooved ball bearing

Area above grooved ball bearing	Dimension “a”	Top spacer
Up to gearbox manufacturing date 09 04 6	10 mm	No
From gearbox manufacturing date 10 04 6 onwards	10.7 mm	Yes

In the gearbox housing, the area below the seat for the grooved ball bearing has also been modified -arrow-.

Area below bearing seat		Bottom spacer
Up to gearbox manufacturing date 09 04 6	Not modified	No
From gearbox manufacturing date 10 04 6 onwards	Slightly deeper	Yes

–  If necessary, fit a spacer (outside diameter = 85 mm) -1- onto grooved ball bearing -2-.

Gearboxes with flattened sides on grooved ball bearing for input shaft -A- and bearing mounting -B-: l  A spacer must not be fitted above or below the grooved ball bearing. l  Flattened sides -A- on grooved ball bearing and bearing mounting -B- in gearbox housing must be aligned. –  Mark flattened sides with paint. –  Copy markings onto top area of grooved ball bearing and top area of bearing mounting on gearbox housing (⇒ next illustration). –  Using hot air blower -V.A.G 1416-, heat area around seat of input shaft ball bearing in gearbox housing for approx. 10 minutes to approx. 100°C.   Note Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing.

–  Align marking -A- on grooved ball bearing with marking -B- on gearbox housing and fit gearbox housing.

Continued for all gearboxes: –  Using hot air blower -V.A.G 1416-, heat area around seat of input shaft ball bearing in gearbox housing for approx. 10 minutes to approx. 100°C.   Note Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing. –  Apply sealing paste -AMV 188 200 03- evenly to sealing surface of clutch housing. –  Fit gearbox housing and tighten new bolts -A-, -B- and -C- to specified torque. Allocation of bolts: A -  Bolt with captive washer B -  Bolt without washer C -  Bolt with captive washer

–  If a spacer was fitted on the grooved ball bearing before installing the gearbox housing, a spacer -1- (outer diameter = 78.6 mm) must also be fitted after installing the gearbox housing -2- → Anchor.

–  Install circlip -1- for input shaft grooved ball bearing. –  Remove support bridge -30 - 211 A- for input shaft. –  If stop sleeve for selector shaft has been removed, drive it in now → Fig. (drive in until tool reaches stop).

–  Turn gearbox on assembly stand so that opening for selector shaft faces up. –  Insert selector shaft -1- into bottom mounting -2- and into selector forks -3-.   Note The sealing cap is removed to give a better illustration.

–  Now push selector shaft -1- against stop sleeve -2- in direction of -arrow- and run selector finger -3- down through selector forks and onto stop. l  Selector mechanism cover -4- should be parallel to joint surface on gearbox housing. l  Selector shaft should move up and down easily (gate selector movement).   Note If the selector mechanism cover is not parallel with the joint surface, the selector shaft is not seated in its bottom mounting.

–  Tighten bolts -3- for selector mechanism cover -4-. –  Screw in locking bolt -2-; angled rod -arrow- must be released. –  Install reversing light switch -F4--1-. –  Install flange shaft (left-side) → Chapter.

–  Drive in input shaft oil seal. –  Install clutch slave cylinder with release bearing → Chapter. –  Select all gears.

–  Drive sealing cap into gearbox housing onto stop. Attach bevel box to gearbox as follows:   Caution The oil seal between the bevel box and the gearbox can be damaged. Turn flange shaft while fitting bevel box with flange shaft (right-side) onto gearbox. –  On manual gearbox, grease splines on differential with grease for clutch plate splines -G 000 100-. –  Push bevel box fully onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together. –  If the teeth 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 could break off.

–  Tighten all 4 bolts -arrows- securing bevel box to gearbox (illustration only shows 3 bolts). Tightening torques → Item –  Install flange shaft (right-side) → Chapter.