Audi Workshop Service and Repair Manuals

Assembling gearbox If the gearbox housing, the final drive gear set or the hollow shaft have been renewed, you must first re-determine the thickness of the shim “S6” → Chapter. The shim is located on the hollow shaft and is responsible for the proper positioning of the 2nd speed selector gear. Always renew the double angular contact ball bearing on the pinion shaft when renewing the final drive gear set. The differential must be removed to check the double angular contact ball bearing for wear (running noises). The bearing should not “catch” and should run smoothly when the installed pinion shaft is rotated.   Note t  Carefully use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. t  Clean the thread for the 12-point nut on the hollow shaft. t  Lubricate all needle bearings and synchro-rings with gear oil before fitting. t  Thoroughly clean housing joint surfaces. t  Check synchro-rings for wear → Chapter –  Fit shim “S3” in gearbox housing.

–  Lubricate outer races -3- and -4- with gear oil. –  Carefully push pinion shaft -1- with double angular contact ball bearing into gearbox housing -2- by hand (press down top outer race -3-).   Note Using hot air blower, heat area around seat of bearing in gearbox housing if necessary. Make sure that outer races -3- and -4- are kept straight when inserting and that they remain attached to each other. Otherwise the seal -6- can be damaged by the pinion gear -5-. The bearing must be renewed if the seal of the double angular contact ball bearing is damaged.

–  Fit shim “S4” and retaining plate -A- (can only be fitted in one position). –  Clean threads of old bolts -arrows- with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- and tighten to 30 Nm in diagonal sequence. –  Fit hollow shaft needle bearing onto pinion shaft.

–  Then insert hollow shaft -1- together with input shaft -2- and selector rods -3- and -4- in gearbox housing (guide hollow shaft over pinion shaft -arrow-).

–  Fit lug -arrow A- on oil guide panel -1- into recess -arrow B- in gearbox housing.

–  Guide bearing mounting -A- over input shaft and hollow shaft and fit onto oil guide panel -C-. The mounting -B- for reverse shaft must be fitted on the bearing mounting.

Checking synchro-rings for 1st, 2nd and reverse gear for wear –  Check outer friction surface on inner ring for scoring or visible traces of wear and renew if necessary. –  Check inner friction surface of synchro-ring for scoring or visible traces of wear and renew if necessary. –  Fit inner ring, intermediate ring and synchro-ring onto cone of selector gear/clutch unit and rotate rings to achieve proper seating.   Note To achieve proper seating, rotate synchro-rings approx. one turn while pressing down rings simultaneously. –  Then measure gap -a- using a feeler gauge.

Gap -a-	Wear limit
1st and 2nd gear	0.7 mm
Reverse gear	0.7 mm

Note Renew inner ring, intermediate ring and synchro-ring for the corresponding gear together.

Identification of reverse gear synchro-rings -A- and 1st/2nd gear synchro-rings -B- 1 -  Reverse gear synchro ring: the lugs -arrow 1- have a smooth surface. 2 -  Reverse gear intermediate ring: the friction surfaces -arrows 2- are coated with sintered particles (brass colour). 3 -  Reverse gear inner ring: has no inner friction surface -arrow 3-. 4 -  Synchro-ring for 1st and 2nd gear: the lugs are fitted with 2 projections each -arrow 4-. 5 -  Intermediate ring for 1st and 2nd gear: the friction surfaces -arrows 5- are carbon-coated (black coating). 6 -  Inner ring for 1st and 2nd gear: the inner friction surface -arrow 6- is carbon-coated (black coating).

Installation position of synchro-rings for 1st, 2nd and reverse gear   Note t  If components are not being renewed, make sure they are re-installed on the same gear. t  Do not interchange synchro-rings for reverse gear with synchro-rings for 1st and 2nd gear → Fig.. –  Fit inner ring -2- onto selector gear -1-/clutch unit. –  Fit intermediate ring -3-. Lug -B- must be inserted into recess -A-. –  Fit synchro-ring -4-. Guide lugs -C- through recess -arrow-. –  Place 2nd speed selector gear with needle bearing and synchro-rings onto hollow shaft. –  Then fit synchronising hub for 1st and 2nd gear.

Installation position of locking collar for 1st and 2nd gear l  The side with asymmetric splines -arrow- must point towards 2nd gear.

Assembling 1st and 2nd gear locking collar/synchronising hub –  Fit locking collar -A- (in installation position → Fig.) together with selector fork for 1st and 2nd gear -C- over synchro-hub -B-.   Note The locking collar can only be fitted over synchro-hub in one position, gaps in splines -arrow 1- and -arrow 2- have different widths. Detach synchro-hub -B- from hollow shaft and turn upside down if necessary. –  Then position thrust blocks in recesses in synchronising hub and press thrust blocks in direction of -arrow 3- into recesses in locking collar. The locking collar must be held in the centre position.

–  Heat needle bearing inner race -1- for 1st speed selector gear to approx. 100 °C, fit and drive onto stop.

Assembling locking collar and reverse selector gear 1 -  Reverse selector gear 2 -  Locking collar 3 -  Thrust blocks –  Push locking collar over reverse selector gear. Installation position: l  The pointed teeth -arrow A- of the locking collar point away from the driving teeth -arrow B- of the reverse selector gear. l  Recesses for thrust blocks -3- in reverse selector gear -arrow C- and locking collar -arrow D- must align. –  Then position thrust blocks in recesses on reverse selector gear and press thrust blocks into recesses in locking collar.

–  Place 1st speed selector gear -C- with needle bearing and synchro-rings onto needle bearing inner race. –  Fit thrust washer for 1st gear and reverse gear onto hollow shaft. –  Fit reverse selector gear -A- (with locking collar fitted) together with reverse gear selector rod -B-.

–  Fit reverse shaft -1- with recess -arrow A- onto lug -arrow B- of reverse shaft mounting -2-.

–  Fit reverse gear wheel -1- with needle bearing onto reverse shaft; teeth of reverse gear wheel must point towards reverse selector gear. –  Fit clutch unit -2- with needle bearing and synchro-rings onto hollow shaft. –  Fit magnet -3- into rib in gearbox housing.

–  Move selector rods to neutral -arrow-. –  Drive in locking bushes -1- to -4- for selector rods as far as stop using tube -VW 421-.   Note Do not interchange locking bushes for selector rods and selector shaft. –  Check whether the two dowel sleeves for centring gearbox cover to gearbox housing are fitted in gearbox cover. –  Apply sealing paste -AMV 188 001 02- evenly and not too thickly onto contact surfaces between gearbox housing and gearbox cover.

–  Fit gearbox cover -B- onto gearbox housing. Do not screw in bolts -A- at this stage. –  Screw in bolt -arrow 2- into reverse shaft hand-tight. –  Screw new bolts -arrows 1- into bearing mounting and tighten hand-tight. –  Then tighten the 13 bolts -A- to 24 Nm. –  Then tighten bolts -arrows 1- to 27 Nm and bolt -arrow 2- to 24 Nm. –  Lubricate new O-ring -C- with gear oil and insert into circumferential groove on gearbox cover. –  Then turn gearbox in assembly stand in horizontal position.

–  Lock hollow shaft in position by moving selector rods -1- to -4- in direction of -arrow-.

–  Now tighten 12-point nut on hollow shaft to 75 Nm. A -  Torque wrench –  Then set selector rods to neutral position. –  Turn gearbox on assembly stand so that gearbox cover faces upwards.

–  Fit spacer ring -5- over 12-point nut on hollow shaft. –  Install outer race -4- and inner race -3-. These components are a push fit and can be installed by hand. If you have renewed the pinion shaft (final drive gear set), you must now re-determine the thickness of the circlip -1- and the shim(s) -2- for the tapered roller bearing on the pinion shaft → Anchor.

The thickness of the circlip -1- and the shim(s) -2- is determined according to the following procedure: –  The gap after fitting shim(s) and circlip available as spare parts must be max. 0.10 mm (measured between shim -2- and tapered roller bearing inner race -4-. –  Check the gap with a feeler gauge -3-.   Note The circlip -1- must be properly seated in the base of the groove and the tapered roller bearing inner race -4- must be pressed in direction of -arrow-. –  Determine shim(s) and circlip from table. Part numbers → Electronic parts catalogue “ETKA”. The following shims are available:

Shim thickness (mm) → Note
0.7	1.1	1.5
0.8	1.2	1.6
0.9	1.3
1.0	1.4

1)  The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if necessary. The following circlips are available:

Circlip thickness (mm)
1.70	1.80	1.90
1.75	1.85

–  Install determined shim(s) and circlip.

–  Push Torsen differential onto splines on hollow shaft and press in direction of -arrow-. –  When doing this, measure distance -a- between flat surface of grooved ball bearing outer race -1- and flat surface of gearbox cover flange. Determine required shim from table → Anchor. The following shims are available:

Measuring range	Shim
Measured value (mm)	Thickness (mm)
109.88 … 110.00	1.65
109.91 … 110.15	1.45
110.16 … 110.45	1.20
110.41 … 110.70	0.95
110.66 … 110.95	0.70
110.91 … 111.20	0.45

Note Select correct shims from → Electronic parts catalogue “ETKA”. –  Turn gearbox in assembly stand into horizontal position.

–  Insert dished spring -B- into Torsen housing -A-. l  Installation position of dished spring: inner diameter (convex side) faces flange shaft in Torsen housing. –  Position determined shim -C- on dished spring -B-. –  Fit spring -D- onto flange shaft in Torsen housing –  Then fit Torsen housing onto gearbox cover.

–  Tighten bolts -arrows- to 24 Nm.

–  Push assembly sleeve -01E 311 120--A- onto selector shaft -B-.   Note To avoid damaging oil seal -C-, oil seal and selector shaft must only be fitted using assembly sleeve -01E 311 120--A-. l  Selector rods must be in neutral position. –  Install complete selector shaft. l  Installation position: Chamfer of selector shaft points downwards.

–  Push selector shaft -A- into gearbox as far as it will go, simultaneously inserting pin -B-.   Note On pins with lug, the end with the lug must be inserted into the gearbox housing drilling.

–  Fit cover -B- with new O-ring. –  Clean threads of bolts -arrows- with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- and tighten to 24 Nm. A -  Locking bushes for selector shaft   Note

t  Install only version -B- of locking bushes for selector shaft with flanged edge -arrow 2-. t  If the gearbox is fitted with selector shaft locking bushes of type -A-, these must always be replaced with locking bushes of type -B-. Parts No. → Electronic parts catalogue “ETKA”. t  Version -B- can be re-used if already installed.

–  Drive in selector shaft locking bushes → Anchor using tube -VW 421-.

–  Then install circlip -arrow- in front of grooved ball bearing for input shaft.

–  Lubricate new O-ring -arrow- with gear oil before fitting into circumferential groove on gearbox housing. –  Fit a thin insulating hose or shrink hose onto input shaft splines. –  Pack space between sealing lip and dust lip of oil seal in guide sleeve half-full with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of guide sleeve.

–  Push guide sleeve -2- over input shaft and into gearbox housing. –  Remove insulating hose/shrink hose. –  Fit retaining piece -1-. –  Clean threads of bolts -arrows- with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- and tighten to 24 Nm. –  Insert intermediate piece -3- in gearbox housing.

–  Before installing clutch release lever -3-, apply a thin coat of copper grease to contact surface for operating rod of clutch slave cylinder. –  Install clutch release lever together with release bearing. –  Clean thread of bolt -1- with a wire brush. –  Position leaf spring -2- onto bolt -1-. –  Then insert bolt -1- with locking fluid -AMV 185 101 A1- and tighten to 24 Nm. –  Select all gears.