Audi Workshop Service and Repair Manuals

Servicing gearbox cover

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Multi-purpose tool -VW 771-

t	Adapter -VW 771/44-

t	Support plate -VW 801-

t	Thrust piece -32 - 111-

t	Thrust plate -40 - 105-

t	Locking pin -2064-

t	Assembly tool -3253-

t	-1-Internal puller -Kukko 21/2-

t	-1-Internal puller -Kukko 21/4-

t	-4-Counter-support -Kukko 22/2-

t	Depth gauge

1 -	Gearbox cover

2 -

Dowel pin

q

2 x

q	Insert in gearbox cover

q	Drive in until flush with rear surface of housing flange

3 -	Ball sleeve

q	For reverse gear selector rod

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Measuring installation depth → Fig.

4 -	Ball sleeve

q	For selector rod for 1st and 2nd gear

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Measuring installation depth → Fig.

5 -	Roller bearing

q	Bearing for input shaft in gearbox cover

q	Always renew

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Peen to secure after installing → Fig.

Pulling out ball sleeve from gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 14.5...18.5 mm, e.g. -Kukko 21/2-   Note A stud (M10) and adapter -VW 771/15- can also be used instead of adapter -VW 771/44-.

Pressing ball sleeve into gearbox cover –  Fit ball sleeve so that side with lettering (thicker metal) faces locking pin -2064-. Fit the small Ø of locking pin -2064- in the ball sleeve. –  Support gearbox cover below bearing seat using thrust plate -40 - 105-. Installation depth of ball sleeve → Fig..

Installation depth of ball sleeve in gearbox cover –  Press in ball sleeve for reverse gear selector rod -1- and for 1st/2nd gear selector rod -2- to dimension -a- = 250.5 ± 0.5 mm.

Pulling out roller bearing from gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 30...37 mm, e.g. -Kukko 21/4- –  Eliminate peening depressions if necessary.   Note Always renew roller bearing after pulling out.

Carefully press in new roller bearing into gearbox cover until limit stop. Support gearbox cover below bearing seat using thrust piece -32 - 111-. –  Secure roller bearing after pressing in by peening into gearbox cover → Fig..

Securing roller bearing in gearbox cover by peening. –  Use a blunt punch with a ball shaped end (ball Ø approx. 5 mm) to peen in position. –  The roller bearing -1- is secured with 3 peening positions offset by 120° -arrows-. Observe position and Ø of peening positions: t  Dimension -a- = 2 mm t  Dimension -b- = 3 mm