Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Drift VW 222 A
• ◆ Drift VW 295
• ◆ Adapter VW 295 A
• ◆ Thrust plates VW 401 and VW 402
• ◆ Press tools VW 407 and VW 408 A
• ◆ Tubes VW 415 A and 416 B
• ◆ Thrust pad VW 447 i
• ◆ Multi-purpose tool VW 771
• ◆ Drift 30-24
• ◆ Sleeve 30-100
• ◆ Thrust plate 40-105
• ◆ Press tool 40-202
• ◆ Separating tool Kukko 17/2
• ◆ Internal puller Kukko 21/4

Notes:

• ◆ When installing new gears or the input shaft consult technical data =>from Page 00-3.
• ◆ The position of the ball bearing will be affected if -Items 35-19.

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 1
• ◆ Determining thickness => Adjus-ting input shaft, Page 35-19
• Ball bearing
• ◆ Removing and installing
  

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 2
• ◆ Determining thickness => Adjus-ting input shaft, Page 35-19
• Gearbox housing
• ◆ Housing manufactured from aluminium or magnesium
  => Page 34-85
• Needle bearing
• ◆ Secured with bolt => Fig.1
• ◆ Tapping out => Fig.2
• ◆ Selecting correct needle roller bearing for input shaft => Fig.3
• ◆ Installation position => Fig. 4.
• ◆ Pressing in => Fig. 5
• ◆ Locking => Fig.6

• Input shaft
• ◆ With oil feed sleeve
• ◆ Knocking in oil feed sleeve => Fig.7
• ◆ Adjusting => Page 35-19
• ◆ Selecting correct needle roller bearing for input shaft => Fig.3
• Needle roller bearing for 3rd gear
• ◆ Mark
• 3rd speed sliding gear
• Spring
• ◆ Insert in 3rd speed sliding gear => Fig.13
• ◆ Allocation of spring to sliding gear

=> Parts List

• Synchro-ring for 3rd gear
• ◆ Check for wear => Fig.14

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 3
• Synchro-hub for 3rd and 4th gear
• ◆ High collar faces 3rd gear
• ◆ Pressing off => Fig.12
• ◆ Pressing on =>Fig.17
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 4
• ◆ If the synchro-hub is replaced re-determine thickness => Fig. 16
• Locking collar for 3rd and 4th gear
• ◆ Installation position => Fig. 18.
• Synchro-ring for 4th gear
• ◆ Check for wear => Fig.14

• Spring
• ◆ Insert in 4th speed sliding gear => Fig.13
• ◆ Allocation of spring to sliding gear

=> Parts List

• 4th speed sliding gear
• Needle roller bearing for 4th gear
• ◆ Mark
• 5th gear wheel
• ◆ Pressing off => Fig.11
• ◆ Pressing on =>Fig.19
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 5
• ◆ If the 5th gear wheel is replaced re-determine thickness => Fig. 16

• Roller sleeve
• ◆ Replace
• ◆ Will be damaged during removal
• ◆ Pulling out =>Fig.8
• ◆ Installation position => Fig. 9.
• ◆ Tapping in =>Fig.10
• Sleeve
• ◆ Made of plastic
• Gearbox cover
• ◆ Aluminium version: must only be fitted to an aluminium gearbox housing
• ◆ Magnesium version: must only be fitted to a magnesium gearbox housing
• ◆ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces

→ Fig.1    Unscrewing securing bolt -arrow- for needle roller bearing

• ‒ Unscrew securing bolt -arrow-.

Note:

Bolt is not fitted on all versions.

→ Fig.2    Driving out needle roller bearing

→ Fig.3    Selecting correct needle roller bearing for input shaft

Note:

To avoid damage resulting from incorrect installation, check the following after replacing the input shaft.

• ◆ It must be possible to guide input shaft into place.
• ◆ The input shaft must not have any free play.

→ Fig.4    Installation position of needle roller bearing

Distance -a- from lower edge of straight-edge to upper edge of needle roller bearing = 39.5 mm

Note:

Measure distance from top edge of straight-edge and subtract the width of the straight-edge from the measured distance.

→ Fig.5    Pressing in needle roller bearing

→ Fig.6    Screwing in securing bolt -arrow-

Note:

Bolt is not fitted on all versions.

• ◆ Aluminium gearbox housing

• Tighten to 25 Nm

• ◆ Magnesium gearbox housing

• Tighten to 20 Nm

→ Fig.7    Knocking oil feed sleeve into input shaft

• ◆ Installation position:

• Flanged edge on oil feed sleeve faces towards fitting tool

• ◆ Installation depth:

• 3.5 mm below top edge

→ Fig.8    Pulling out roller sleeve

A - Internal puller, e. g. Kukko 21/4, 22 ... 28 mm

• ‒ Before fitting internal puller destroy the plastic sleeve inside the roller sleeve.

→ Fig.9    Installation position of roller sleeve

• ◆ Distance a = 216 mm

→ Fig.10    Driving in roller sleeve

→ Fig.11    Pressing off 5th gear wheel

• ‒ Remove circlip before pressing off.

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

→ Fig.12    Pressing off synchro hub for 3rd and 4th gear

• ‒ Remove circlip before pressing off.
• ‒ Press 3rd gear synchro ring (arrow) towards 3rd gear wheel, then fit separating device -A-.

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

→ Fig.13    Inserting spring in sliding gear

The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.

→ Fig.14    Checking synchro-ring for wear

• ‒ Press synchro-ring into locking collar and measure gap -a- with a feeler gauge at positions -A-, -B- and -C-.
• ‒ Add the measured values and divide by 3.

The calculated value must not be less than 0.5 mm.

→ Fig.15    Installation position of circlips

• ◆ Circlips -1- and -2- secure the input shaft ball bearing.

• Determining thickness => Adjusting input shaft, Page 35-19.

• ◆ Circlip -3- secures the 3rd and 4th gear synchro hub.

• Thickness: 2.00 mm. Identification: brown colour.

• ◆ Circlip -4- secures the 3rd and 4th gear synchro hub.

• Determining thickness => table on Page 35-16. Identification: blue colour.

• ◆ Circlip -5- secures the 5th gear wheel.

• Determining thickness => table on Page 35-16.

→ Fig.16    Determining thickness of circlip

• ‒ Determine the thickest circlip that will just fit and install it.
• ‒ Determine circlip as accurately as possible from table. Part numbers

=> Parts List

Available circlips for 3rd and 4th gear synchro-hubs

Available circlips for 5th gear wheel

→ Fig.17    Pressing on synchro hub for 3rd and 4th gear

• ◆ Installation position:

• High inside collar faces 3rd gear

→ Fig.18    Installation position of locking collar

Different types of locking collar are installed: version -A- with chamfered edge, arrow 1, or version -B- with large shoulder, arrow 3.

• ◆ Installation position:

• Chamfered edge -arrow 1- faces 4th gear
• Small shoulder -arrow 2- faces 3rd gear
• Large shoulder -arrow 3- faces 4th gear

→ Fig.19    Pressing on 5th gear wheel

• ‒ Heat 5th gear wheel to approx. 100 oC before pressing on.

• ◆ Installation position:

• High collar faces reverse gear