Audi Workshop Service and Repair Manuals

• ‒ → Secure gearbox in assembly stand VW 540.
• ‒ Place drip tray underneath and drain gearbox oil.

• ‒ → Slacken bolt -1-, remove leaf spring -2- and press back detent -arrow-.
• ‒ Remove clutch release lever -4- together with release bearing -3-.
• ‒ Unbolt guide sleeve.

• ‒ Pierce rubber in centre of sealing cap with a large screwdriver.
• ‒ → Insert screwdriver sideways between sealing cap and oil collector and push in until it touches the edge. Then turn screwdriver to lever off sealing cap.

• ‒ → Insert screwdriver into hole and lever off oil collector.

• ‒ → Remove locking bolts -A- for selector shaft from gearbox housing.
• ‒ Mark fitting locations of aluminium and steel bolts. (Bolts must not be interchanged when installing.)
• ‒ Remove 3 bolts -B- for cover for selector shaft, take off cover.
• ‒ Pull out selector shaft.

• ‒ → Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates -arrows-.

• ‒ → Unscrew multi-point socket head bolt -A- for input shaft.

• ‒ → Pull off 2nd inner race for four-point bearing for input shaft.

Note:

Internal puller 3275 engages in a circular groove in the inner race when pulling off.

• ‒ Remove bolts securing end cover to bearing plate.
• ‒ Take off end cover together with end cover/bearing plate gasket.
• ‒ → Pull off 5th speed sliding gear and spring together with 1st inner race -A- for four-point bearing for input shaft.

•     B -    Two arm puller, e.g. Kukko 20/10

• ‒ Take off 5th gear synchro-ring.

• ‒ Take off circlip for 5th speed gear.
• ‒ Lock input shaft in position by engaging two gears .
• ‒ → Pull off 5th speed gear.

•     A -    Two-arm puller, e.g. Kukko 20/10

• ‒ → Press out roll pin -A- for selector fork for 5th and 6th gear.

Note:

Do not drive out roll pin as this would damage the selector rod bearing.

• ‒ Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (until stop is felt).

• ‒ → Mark relative positions of locking collar for 5th and 6th gears and synchro-hub (paired) -arrow 1-.

• ‒ → Pull follower together with selector fork and locking collar off selector rod.

• ‒ → Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th speed gears and inner race for 5th speed sliding gear.

•     A -    Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks

• ‒ → Unscrew selector rod locking bolts.

•     A -    1st and 2nd gear
•     B -    3rd and 4th gear
•     C -    5th and 6th gear
•     D -    Reverse gear

• ‒ Mark fitting locations of aluminium and steel bolts. (Bolts must not be interchanged when installing.)
• ‒ Drive out dowel sleeves on bearing plate and remove bearing plate from gearbox housing.
• ‒ Separate bearing plate, drive pinion and internal selector mechanism (as a single unit) from gearbox housing.

• ‒ → Remove circlip from selector rod for 1st and 2nd gear and take off follower -A-.
• ‒ Pull out selector rod -B- for 5th and 6th gear.
• ‒ Remove follower -C- for reverse gear.

• ‒ → Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft.
• ‒ Use right-angled circlip pliers to remove circlip -arrow B- for inner race for cylinder roller bearing.
• ‒ Take out inner race -arrow C- for cylinder roller bearing (not a press fit).

• ‒ → Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing plate.

• ‒ Remove circlip for 6th speed gear.
• ‒ → Press off 6th speed gear.

Note:

Because of the type of fit, it may be possible to press gear off easily.

• ‒ Remove drive pinion from bearing plate together with selector rod and selector fork for 1st and 2nd gears.

Note:

For repair work involving only the drive pinion or input shaft it is not necessary to remove the reverse gear.

• ‒ Take off relay lever for reverse gear.
• ‒ → Unscrew hexagon bolt -D-, take off spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse idler gear.
• ‒ Take out spring, synchro-ring and reverse idler gear.

Removing and installing reverse gear .