Audi Workshop Service and Repair Manuals

Removing and installing input shaft cover Special tools and workshop equipment required

t  Oil seal extractor -T40014-

t  Thrust piece -T40099- t  Ice spray t  Protective gloves t  Safety goggles

Removing l  Input shaft is removed → Chapter –  Pull out oil pipe -arrow- upwards so as to avoid damage.

–  Check all 8 bolts -arrows- of thrust piece -T40099-. l  Bolts should have been screwed in flush to 25 Nm → Assembly instructions for thrust piece T40099.

–  Place input shaft in thrust piece -T40099-. –  Screw oil seal extractor -T40014- into oil seal by hand until tool grips securely in seal. Then tighten the tool using an open-ended wrench. –  Screwing in the rear bolt -arrow- will allow you to pull the oil seal out a little. –  Then re-apply the open-ended wrench so that the oil seal extractor -T40014- firmly engages in the oil seal again and screw in the bolt to further extract the seal. –  Repeat procedure until oil seal is pulled out all the way.

–  Remove retaining ring from input shaft cover -A-. –  Measure and note down thickness of retaining ring once removed.   Note When installing ball bearing, replace circlip with a new one of the same thickness.

–  Clean sealing surface -arrow- of cover.

WARNING Risk of burns Wear protective gloves and safety goggles! –  Apply ice spray for example by way of the opening -arrow 1- for the oil pipe removed to cool the hollow shaft -1- on the inside at the seat -arrow 2- of the bearing “A”-Item 2- (ball bearing for input shaft).   Note t  The illustration shows a sectional view of the shaft. t  The shaft must be cooled to facilitate pressing off of the cover with bearing “A”-Item 2- (ball bearing for input shaft) and to prevent damage.

–  Clean surface of thrust piece -T40099-. –  Place input shaft in thrust piece -T40099-. l  Sealing surface of input shaft should be seated flush on the thrust piece. l  Make sure no objects (such as cable ties or dirt) are trapped between sealing surface of input shaft and surface of thrust piece -T40099-.   Caution Metal particles or dirt will damage the sealing surface of the cover when pressing off and the cover will then have to be renewed. –  In addition, cool the shaft from the outside -arrow- e.g. with ice spray.   Note The shaft must be cooled to facilitate pressing off of the cover with bearing “A” (ball bearing for input shaft) and to prevent damage. –  Place input shaft together with thrust piece -T40099- on thrust plate of hydraulic press.   Note The thrust piece -T40099- should rest as firmly as possible on the hydraulic press.

–  Hold shaft from underneath and at the same time use hydraulic press to press shaft out of cover.

–  Set down input shaft on assembly tool -T10219/1-.   Note Screwdriver and arrows can be disregarded.

Installing –  Replace the bearing “A” (ball bearing for input shaft) in the input shaft cover → Chapter. –  Place input shaft cover on input shaft and press on as far as possible by hand.

–  Place input shaft -B- on thrust plate -VW 401-.   Caution Take care to keep the input shaft straight and aligned centrally when positioning it beneath the press tool of the hydraulic press, as the input shaft may otherwise tilt to one side when pressure is applied to the cover. –  Use hydraulic press and tube -VW 416 B- to press input shaft cover -A- all the way home on the input shaft.

Fitting retaining ring for input shaft cover –  Replace retaining ring -A- with a new one of the same thickness when installing.   Note Check that retaining ring is seated properly.

Installing oil pipe –  Assess wear on gearbox components → Chapter. –  Renew O-ring -2- on oil pipe. l  The oil pipe is pressed into the input shaft with the O-ring -2- first. l  You should feel oil pipe engage. Rotor vanes -arrow A- on oil pipe should be completely inside input shaft.

–  Press oil pipe -arrow- down into input shaft as far as stop. l  With oil pipe fully inserted, distance from end of oil pipe to input shaft should be approx. 11.5 mm. If the distance is less, the oil pipe may be damaged (the end could have broken off if the oil pipe was pushed in too far). If the distance is larger, the oil pipe is not pushed in far enough.   Caution t  Do not put down input shaft on the protruding oil pipe -arrow-, as oil pipe would then become damaged. t  A damaged oil pipe will cause drive-away problems or complete gearbox failure.