Audi Workshop Service and Repair Manuals

Assembly sequence - removing and installing gearbox housing cover and 5th gear   Note t  If only the 5th gear has to be removed, please refer to the work sequence described below. t  If the gearbox housing has to be removed, please refer to the procedure: Dismantling and assembling complete gearbox → Chapter.

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Drift -VW 295-

t	Drift sleeve -VW 244 B-

t	Hot air blower -V.A.G 1416-

t	Torque wrench -V.A.G 1331-

t	Support bridge -30-211A-

t	Thrust piece -32 - 111-

t	Thrust piece -T10030/4-

t	Thrust piece of assembly tool -T10030/4-

t	Tube -VW 416 B-

t	Puller -T10309-

t	Two-arm puller -T10040-

t	With claws -T10040/2A-

t	Support bridge -T10323-

t	Assembly tool -3253/7-

t	Press tool -VW 433-

t	Thrust plate -40 - 105-

t	Torque wrench -V.A.G 1332-

Special tools and workshop equipment required

t  Two-arm puller -Kukko 20-10- t  Stud M8 x 100 mm Removing –  Remove clutch release lever and release bearing → Chapter. l  The bearings of the input shaft and output shaft must not be damaged when removing and installing 5th gear.

l  For this reason, when attaching the gearbox to gearbox support -VW 353-, you must first attach the following tools to provide the necessary support: Below input shaft: t  Support bridge -30-211A- t  Thrust piece -32 - 111- t  Thrust piece -T10030/4- l  The input shaft should not be supported by the thrust piece -32 - 111- until it becomes necessary later on. Below bearing mounting for output shaft: t  Support bridge -T10323- t  Assembly tool -3253/7- t  Press tool -VW 433-

–  Secure gearbox on gearbox support -VW 353-.

–  Unbolt gearbox housing cover -arrow-.

–  Check whether claws -T10040/2A- can be applied correctly below 5th gear wheel.

If claws -T10040/2A- cannot be applied correctly:
-A- Claws -T10040/2A- foul against: t  side of gearbox housing t  ribs in gearbox housing below gear wheel	In this case the 5th gear synchro-hub, 5th gear wheel and gearbox housing have to be removed together → Chapter.
-B- Claws -T10040/2A- foul against ribs in gearbox housing below gear wheel.

If claws -T10040/2A- can be applied correctly:

5th gear can be removed separately → Fig.

Removing 5th gear separately –  Remove 5th gear selector fork as follows: –  Cover over openings with a cloth. –  Move selector fork -1- to neutral. –  Then remove both bolts -2- for pivot pins. –  Pull out pivot pins in direction of -arrows A-. –  Take out selector fork in direction of -arrow B-.

–  Remove bolts -A- for synchro-hub and 5th gear wheel; to do this engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  After engaging both gears the input shaft and output shaft are locked; the synchro-hub and gear wheel cannot turn. The two bolts can now be loosened.   Note If the shafts are not being renewed, carefully clean residual locking compound out of tapped holes using a thread tap. Pulling off synchro-hub for 5th gear together with locking collar and locking pieces Use puller -T10309-. –  First insert shell half -T10309/1- between 5th gear wheel -A- and mounting for 5th gear selector fork -B-.

l  Shell half -T10309/1- must be positioned underneath synchro-ring. –  If necessary, press shell half into end position. –  Then turn shell half -T10309/1- to opposite side in direction of -arrow-.

–  Introduce thread insert -T10309/3- into shell half. –  Now fit second shell half -T10309/1- and slide tube -T10309/2- onto tool. –  Please check synchro-hub for damage after removal. –  Renew synchro-ring for 5th gear. –  Remove 5th speed selector gear with needle bearing.

–  Pull off 5th gear wheel. –  First fit claws -A-. B -  Hexagon bolt (M10 x 20), 17 mm   Note Ensure that the claws do not bend outwards when pulling off the gear wheel. Check 5th gear wheel for damage after removal. Installing Installing 5th gear → Chapter. –  Install gearbox housing cover → Chapter. –  Install clutch release lever and release bearing → Chapter. –  Fill up gear oil; capacities → Chapter.