Audi Workshop Service and Repair Manuals

Assembly sequence - dismantling and assembling gearbox Removing and installing input shaft ball bearing, multi-function sender, input shaft, pinion shaft, selector rods and gearbox cover

Special tools and workshop equipment required

t	Retaining plate -VW 309-

t	Gearbox support -VW 353-

t	Fitting tool -3235- or fitting tool -T10246-

t	Multi-point bit -3357-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/2-

t  Drip tray, e.g. -VAS 6208- t  Sealants -AMV 188 001 02-   Note t  It is not necessary to remove the differential to remove the above-mentioned components. t  Removal is only necessary when adjustment work has to be carried out → Chapter „Table of adjustments“. Dismantling gearbox –  Place drip tray e.g. -VAS 6208- under the gearbox. –  Use multi-point bit -3357- to remove drain plug and drain gear oil.

–  Secure gearbox to assembly stand.

–  Remove clutch release lever -A- together with release bearing.   Note Before pulling off guide sleeve -B-, cover splines on input shaft with a shrink-fit hose to protect oil seal. –  Remove guide sleeve -B- –  Remove dished spring -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 ball bearing for input shaft out of gearbox housing.

–  Remove the circlip -arrow- behind the ball bearing for input shaft. –  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 multi-function sender.

–  Remove relay shaft bolts -arrows-.

–  Unscrew detent segment -arrow- and swing it out.

–  The input shaft -A-, the pinion shaft-B-, the relay shaft -C-, the selector rods-D- with selector shaft and the selector forks-E- must be carefully pulled out together. Assembling gearbox   Note If the input shaft ball bearing, the input shaft or the gearbox housing have been replaced, it is necessary to re-determine the thickness of the circlips for the input shaft before installing the components → Chapter „Adjusting input shaft“.

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

–  Assemble the input shaft -A-, the pinion shaft-B-, the relay shaft -C-, the selector rods -D- with selector shaft and selector forks -E- together. –  Install these components together into the gearbox housing.   Note If necessary, the relay shaft -C- and the selector shaft can also be fitted later → Anchor and → Anchor.

Location of selector 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 in direction of -arrow-.

–  Now install relay shaft -A-. –  Insert selector shaft -B- sideways onto drilling in gearbox housing and fit into mounting eye. –  Then pivot selector shaft carefully into position in direction of -arrow-.

–  Then fit detent segment and secure -arrow-.

–  Fit relay shaft bolts -arrows-. –  Renew O-ring for multi-function sender.

–  Carefully insert multi-function sender and secure -arrows-.

Check whether the dowel sleeves for the 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 circlip for input shaft ball bearing -arrow-. –  Slide ball bearing onto input shaft. t  Position: closed side of ball cage faces towards gearbox housing.

–  Pressing in ball bearing: –  Slide thrust piece -A- of fitting tool onto input shaft. –  Position fitting tool behind splines for clutch plate. –  Screw in bolts -B- until they make contact. l  The bolts locate in the recess in the thrust plate -A-.   Note Fitting tool -T10246- can also be used if fitting tool -3235- is not available. –  Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).

–  Now fit front circlip -D- for input shaft ball bearing. –  Then fit dished spring -C-. l  Position: convex side towards guide sleeve -B-.   Note Before fitting guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.

–  Fit guide sleeve -B- for release bearing with new O-ring → Chapter. –  Remove shrink hose. –  Fit clutch release lever -A- and release bearing → Chapter.