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Dismantling and assembling sequence > < Removing and installing 1st, 2nd and reverse gear - exploded view

A4 Mk2

Removing and installing input shaft, hollow shaft, pinion shaft and selector rods - exploded view
   
Removing and installing input shaft, hollow shaft, pinion shaft and selector rods - exploded view
1 - Bolt, 24 Nm
q   Apply locking fluid -AMV 185 101 A1- when fitting
2 - Leaf spring
3 - Intermediate piece
q   Insert in hole in gearbox housing.
4 - Clutch release lever
q   With release bearing
5 - Bolt, 24 Nm
q   2 x
q   Apply locking fluid -AMV 185 101 A1- when fitting
6 - Retaining piece
q   For guide sleeve
7 - Guide sleeve
q   With oil seal
q   Removing input shaft oil seal → Fig.
q   Installing input shaft oil seal → Fig.
8 - O-ring
q   Always renew
q   Lubricate with gear oil
q   Insert in circumferential groove in gearbox cover
9 - Circlip
q   Insert in circumferential groove in input shaft
10 - Selector rod for 5th and 6th gear
q   Installation position → Fig.
q   Only to be renewed complete with pinned selector fork for 5th and 6th gear
11 - Selector rod for 3rd and 4th gear
q   Installation position → Fig.
q   Only to be renewed complete with pinned selector fork for 3rd and 4th gear
q   Modification: with spring-loaded selector fork → Fig., allocate via → Electronic parts catalogue “ETKA”.
12 - Input shaft
q   Dismantling and assembling → Chapter
13 - Bearing mounting
q   Clean locking fluid out of tapped holes (using thread tap or similar)
q   Pressing out and pressing in ball sleeves for selector rods → Fig.
  Note
t  The roller bearing outer races on the input shaft and hollow shaft cannot be renewed individually.
t  The roller bearing outer races must not have any radial clearance in the bearing mounting.
14 - Bolt, 30 Nm
q   6 x
q   Clean thread and apply locking fluid -AMV 185 101 A1- when fitting
15 - Retaining plate
q   Installation position: machined side faces towards gearbox housing (can only be installed in one position).
16 - Shim “S4”
q   Table of adjustments → Chapter
17 - Pinion shaft
q   With double angular contact ball bearing and tapered roller bearing inner race
q   Dismantling and assembling → Chapter
18 - Needle bearing
q   For pinion shaft/hollow shaft
19 - Shim “S3”
q   Table of adjustments → Chapter
20 - Hollow shaft
q   With pressed-on gears for 5th and 6th gear
q   Dismantling and assembling → Chapter
21 - Oil guide panel
22 - Gearbox housing
q   With differential and flange shafts

   
Removing input shaft oil seal
–  Carefully lever out oil seal -arrow- with a screwdriver.
A - Jaw protectors
  Note
The oil seal can also be removed using extractor tool -T20143-.
  A30-0114
Installing input shaft oil seal
–  Lightly oil outer circumference of oil seal.
–  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.
–  Carefully press in oil seal for input shaft as far as it will go.
  A30-0115
Selector rod for 3rd and 4th gear with spring-loaded selector fork -arrow-
  A34-10200
Pressing out and pressing in ball sleeves for selector rods
–  Support bearing mounting with tube -VW 422-.
Fit the small Ø of locking pin -2064- in the ball sleeve.
–  Press out old ball sleeve.
–  Press in new ball sleeve to dimension -a- (approx. 4 mm).
  Note
Fit ball sleeve so that side with lettering (thicker metal) faces locking pin -2064-.
  A34-10156
Installation position of selector rods in gearbox
1 - Selector rod with reverse gear selector fork
2 - Selector rod with selector fork for 1st and 2nd gear
3 - Selector rod with selector fork for 3rd and 4th gear
4 - Selector rod with selector fork for 5th and 6th gear
  A34-10163

Dismantling and assembling sequence > < Removing and installing 1st, 2nd and reverse gear - exploded view