Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 411
• ◆ Press tool VW 412
• ◆ Tube VW 415 A
• ◆ Tube VW 416 B
• ◆ Tube VW 418 A
• ◆ Thrust ring VW 429
• ◆ Thrust plate VW 447 i
• ◆ Thrust piece VW 454
• ◆ Tube VW 519
• ◆ Multi-purpose tool VW 771

• ◆ Support 40-103
• ◆ Tube 2010
• ◆ Thrust pad 3062
• ◆ Fitting tool 3128
• ◆ Separating tool Kukko 17/2
• ◆ Internal puller Kukko 21/1

Notes:

• ◆ When installing new gears or the final drive set consult technical data .
• ◆ Adjustments are required when replacing components marked 1) => adjustment overview, Page 39-44.

• Gearbox housing
• Shim "S3"
• ◆ Adjustment overview
• Outer race for double taper roller bearing 1)
• ◆ Replace together with -Item 5-
• ◆ Pulling out =>Fig.1
• ◆ Pressing in => Fig.3

• Pinion shaft 1)
• ◆ Is mated with crown wheel, renew together as a set
• ◆ Adjusting crown wheel and pinion shaft => Page 39-40
• Inner race for double taper roller bearing 1)
• ◆ Replace
• ◆ Will be damaged during removal
• ◆ Pressing off => Fig.2
• ◆ Pressing on =>Fig.4
• Circlip
• ◆ If the double taper roller bearing hub is replaced re-determine thickness =>Fig.5
• Needle bearing
• ◆ For drive pinion in hollow shaft
• ◆ Lubricate with MoS2-grease

• Hollow shaft1)
• ◆ From 08.98 ä Reinforcements => from Page 35-47
• Needle roller bearing for 1st gear
• Needle roller bearing for 1st gear
• 1st speed sliding gear
• Spring
• ◆ Insert in 1st speed sliding gear => Fig.16
• ◆ Allocation of spring to sliding gear

=> Parts List

• Synchro-ring for 1st gear
• ◆ Checking for wear => Fig.17
• Synchro-hub for 1st and 2nd gear
• ◆ Pressing off => Fig.14
• ◆ Pressing on =>Fig.18

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 -Item 1-
• ◆ If the synchro-hub is replaced re-determine thickness =>Fig.5
• Needle roller bearing for 2nd gear
• Locking collar, 1st and 2nd gear
• ◆ Installation position => Fig.19
• Synchro-ring for 2nd gear
• ◆ Checking for wear => Fig.17
• Spring
• ◆ Insert in 2nd speed sliding gear => Fig.16
• ◆ Allocation of spring to sliding gear

=> Parts List

• 2nd gear sliding gear

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 2
• 3rd gear wheel
• ◆ Pressing off => Fig.13
• ◆ Pressing on =>Fig.20
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 3
• ◆ If the 3rd gear wheel is replaced re-determine thickness =>Fig.5
• 4th gear wheel
• ◆ Pressing off => Fig.12
• ◆ Pressing on =>Fig.21
• ◆ From 08.98 ä Reinforcements => from Page 35-47
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 -Item 4-
• ◆ If the 4th gear wheel is replaced re-determine thickness =>Fig.5
• ◆ From 08.98 ä Reinforcements => from Page 35-47

• Needle bearing
• ◆ From 08.98 ä Reinforcements => from Page 35-47
• 5th speed sliding gear
• ◆ From 08.98 ä Reinforcements => from Page 35-47
• Spring
• ◆ Insert in 5th speed sliding gear => Fig.16
• ◆ Allocation of spring to sliding gear

=> Parts List

• Synchro-ring for 5th gear
• ◆ Checking for wear => Fig.17
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 - Item 5
• 5th gear and reverse gear synchro-hub
• ◆ Pressing off => Fig.11
• ◆ Pressing on =>Fig.22

• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 -Item 6-
• ◆ If the synchro-hub is replaced re-determine thickness =>Fig.5
• Needle bearing
• ◆ For reverse gear
• Locking collar for 5th gear and reverse gear
• ◆ Installation position => Fig.23
• Reverse gear synchro-ring
• ◆ Checking for wear => Fig.17
• Spring
• ◆ Insert in reverse sliding gear => Fig.16
• ◆ Allocation of spring to sliding gear

=> Parts List

• Reverse sliding gear
• Circlip
• ◆ Mark
• ◆ Installation position => Fig.15 -Item 7-
• Inner race for small taper roller bearing 1)
• ◆ Pressing off => Fig.9
• ◆ Pressing on =>Fig.10
• Bushing
• ◆ To secure small taper roller bearing outer race
• ◆ Pulling out =>Fig.6
• ◆ Does not need to be fitted after the small taper roller bearing has been replaced.

• Outer race for large taper roller bearing 1)
• ◆ Pressing out =>Fig.7
• ◆ Pressing in => Fig.8
• Shim "S4"
• ◆ Adjustment overview => Page 39-44
• Ring
• ◆ Holds rubber washer
• ◆ Allocation

=> Parts List

• Rubber washer
• ◆ Compensates variations in length
• ◆ Allocation

=> Parts List

• Gearbox cover

→ Fig.1    Pulling out outer race for double taper roller bearing

• ‒ Remove differential => Page 39-18.
• ‒ Place pressure piece of puller 3128 below the outer race.
• ‒ Fit threaded part of puller 3128 with pressure plate VW 401 onto gearbox housing.

When tightening the bolt the outer race will be pulled out of the housing.

→ Fig.2    Pressing off inner race for double taper roller bearing

• ‒ Remove circlip before pressing off.
• ‒ The outer race -A- must be fitted to press off the inner race.

Note:

Inner race for double taper roller bearing will be destroyed when pressed off.

→ Fig.3    Pressing in outer race for double taper roller bearing

The smaller diameter of thrust pad VW 3062 faces outer race.

→ Fig.4    Pressing on inner race for double taper roller bearing

→ Fig.5    Determining thickness of circlip

• ‒ Determine the thickest circlip that will just fit and install it.
• ‒ The circlips for synchro-hubs, needle bearings and individual gear wheels should also be determined as shown for double taper roller bearing.

• Available circlips and part numbers

=> Parts List

→ Fig.6    Pulling out securing bush for small taper roller bearing outer race

•     A -    Internal puller 12 ... 14.5 mm, e.g. Kukko 21/1

→ Fig.7    Pressing out outer race for taper roller bearing

• ‒ Outer race is pressed out together with ring -Item 35-32.

→ Fig.8    Pressing in outer race for taper roller bearing

→ Fig.9    Pressing off inner race for taper roller bearing

• ‒ Press off inner race with reverse gear sliding gear.

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

→ Fig.10    Pressing on inner race for taper roller bearing

• ‒ Fit circlip before pressing on inner race.

→ Fig.11    Pressing off 5th gear and reverse gear synchro hub

• ‒ Remove circlip before pressing off.
• ‒ Press off synchro hub with 5th speed sliding gear.

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

→ Fig.12    Pressing off 4th gear wheel

• ‒ Remove circlip before pressing off.

→ Fig.13    Pressing off 3rd gear wheel

• ‒ Remove circlip before pressing off.
• ‒ Press 3rd gear wheel off with 2nd speed sliding gear.

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

→ Fig.14    Pressing off synchro hub for 1st and 2nd gear

• ‒ Remove circlip before pressing off.
• ‒ Press off synchro hub with 1st speed sliding gear.

→ Fig.15    Installation position of circlips

• ‒ The circlips for the synchro-hubs, needle roller bearings and individual gear wheels should also be determined as shown in Fig.5.

• ◆ Circlip -1- secures the 1st and 2nd gear synchro hub.

• Identification: blue colour.

• ◆ Circlip -2- secures the needle roller bearing for 2nd speed sliding gear.

• Thickness: 2.50 mm. Identification: blue colour.

• ◆ Circlip -3- secures the 3rd gear wheel.

• ◆ → Circlip -4- secures the 4th gear wheel.

• ◆ Circlip -5- secures the needle roller bearing for 5th speed sliding gear.

• Thickness: 2.00 mm. Identification: brown colour.

• ◆ Circlip -6- secures the synchro-hub for 5th gear and reverse gear.

• Identification: blue colour.

• ◆ Circlip -7- secures the needle roller bearing for sliding gear for reverse gear.

• Thickness: 2.50 mm.

• ‒ Determine circlips according to table: Part numbers

=> Parts List

→ Fig.16    Inserting spring in sliding gear

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

→ Fig.17    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.18    Pressing on synchro-hub for 1st and 2nd gear

• ◆ Installation position:

• High inside collar faces 2nd gear

→ Fig.19    Installation position of locking collar for 1st and 2nd gear

• ◆ Installation position:

• Bevelled edges -arrow 1- faces 2nd gear
• Shoulder -arrow 2- faces 1st gear

→ Fig.20    Pressing on 3rd gear wheel

• ◆ Installation position:

• Groove on gear wheel faces 4th gear

→ Fig.21    Pressing on 4th gear wheel

• ◆ Installation position:

• High inside collar faces 3rd gear

→ Fig.22    Pressing on 5th gear and reverse gear synchro hub

• ◆ Installation position:

• High inside collar faces 5th gear

→ Fig.23    Installation position of locking collar for 5th and reverse gear

Only locking collars with chamfered edges -A- as well as with large shoulders -B- are fitted.

• ◆ Make sure locking collar is correct version for reverse gear wheel => Fig.24
• ◆ Installation position:

• Bevelled edges -arrow 1- faces reverse gear
• Small shoulder -arrow 2- faces 5th gear
• Large shoulder -arrow 3- faces reverse gear

→ Fig.24    Selecting correct locking collar for reverse gear wheel