Audi Workshop Service and Repair Manuals

Notes:

• ◆ It is not necessary to remove the differential to remove the above-mentioned components.
• ◆ Removal is only necessary when adjustments have to be carried out => adjustment overview, Page 39-39.

Special tools, testers and auxiliary equipment required

• ◆ Holding plate VW 309
• ◆ Gearbox support VW 353
• ◆ Pressing-in tool 3235
• ◆ Drip tray V.A.G 1306
• ◆ Taper roller bearing extractor V.A.G 1582
• ◆ Clamping piece V.A.G 1582/2
• ◆ Sealant AMV 188 001 02

Removing

• ‒ Place drip tray V.A.G 1306 underneath the gearbox.
• ‒ Drain gear oil.
• ‒ Secure gearbox to repair stand .

• ‒ → Detach clutch release lever -A- with release bearing.

Notes:

• ◆ Before pulling off guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.
• ◆ Removing oil seal from guide sleeve => Page 30-29.

• ‒ Unscrew guide sleeve -B-.
• ‒ Remove dished washer -C-.
• ‒ Remove circlip -D- in front of input shaft ball bearing.
• ‒ If the ball bearing, input shaft or gearbox housing is not to be replaced, note the thickness of the circlip.

• ‒ → Pull the input shaft ball bearing out of the gearbox housing.

• ‒ → Remove the circlip (arrow) behind the input shaft ball bearing.
• ‒ If the ball bearing, input shaft or gearbox housing is not to be replaced, note the thickness of the circlip.

• ‒ → Unbolt gearbox cover -A- from gearbox housing -B-.

• ‒ → Remove bolts (arrows) and pull out the multi-function sender.

• ‒ → Remove relay shaft bolts (arrows).

• ‒ → Unscrew detent segment (arrow) and swivel it out.

• ‒ → The input shaft -A-, the pinion shaft -B-, the relay shaft -C-, the selector rods -D- with the selector shaft and the selector forks -E- should be carefully pulled out together.

Installing

Note:

If the input shaft ball bearing, the input shaft or the gearbox housing are renewed, it is necessary to re-determine the thickness of the circlips for the input shaft , adjusting input shaft.

• ‒ → Swing the gearbox housing into the position shown. The components listed below can then be fitted more easily.

• ‒ → Put the input shaft -A-, the pinion shaft -B-, the relay shaft -C-, the selector rods -D- with the selector shaft and the selector forks -E- together.
• ‒ Install these components together into the gearbox housing.

Note:

Relay shaft -C- and the selector shaft can also be fitted later =>Fig. V34-1816, Page 34-96.

→ Location of gear shift mechanism in gearbox

•     1 -    Selector fork for 5th gear and reverse gear
•     2 -    Selector fork for 3rd gear and 4th gear
•     3 -    Selector fork for 1st gear and 2nd gear
•     4 -    Relay shaft
•     5 -    Detent mechanism
•     6 -    Selector shaft

Note:

Shown in illustration with input shaft and pinion shaft removed.

• ‒ → Turn gearbox housing and engage 3rd gear (direction of arrow).

• ‒ → Now install relay shaft -A-.
• ‒ Insert selector shaft -B- sideways onto drilling in gearbox housing and assemble into mounting eye.
• ‒ Then turn the selector shaft carefully in direction of arrow.

• ‒ → Then insert the detent segment and bolt it tight (arrow).

• ‒ → Screw in the bolts for the relay shaft (arrow).

• ‒ Replace O-ring for multi-function sender.
• ‒ → Carefully insert multi-function sender and tighten (arrow).

Check whether the dowel sleeves for gearbox cover -A- are fitted in gearbox housing -B-.

• ‒ Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
• ‒ Fit gearbox cover onto gearbox housing.

• ‒ → Fit rear input shaft ball bearing circlip (arrow).
• ‒ Slide the ball bearing onto the input shaft.
• ‒ Installation position: closed side of ball cage faces towards gearbox housing

• ‒ → Press in ball bearing:
• ‒ Slide thrust pad -A- of pressing-in tool onto input shaft.
• ‒ Position pressing-in tool behind splines for clutch plate.
• ‒ Screw in the bolts -B- until they make contact.
• ‒ The bolts bear against the indentations in thrust piece -A-.
• ‒ Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).

• ‒ → Now fit the front circlip -D- for the input shaft ball bearing .
• ‒ Then fit dished washer -C-.
• ‒ Installation position: convex side towards guide sleeve -B-

Notes:

• ◆ Before fitting guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.
• ◆ Installing oil seal in guide sleeve => Page 30-29.

• ‒ → Fit guide sleeve -B- for release bearing.
• ‒ Fit clutch release lever -A- and release bearing.