Audi Workshop Service and Repair Manuals

Dismantling and assembling sequence Removing and installing gearbox housing cover, gearbox housing, selector mechanism, input shaft, output shaft, differential and selector forks

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	Sealing grease -G 052 128 A1-

t	Sealants -AMV 188 200 03-

t	Stud M8 x 100 mm

t	Bolt M10 x 20 mm

t  -1-Two-arm puller, e.g. -Kukko 20/10- with hooks -Matra V/170-

t  Support bridge -30-211A-

t  Thrust piece -32 - 111-

t  Thrust piece -T10030/4- of assembly tool -T10030- Dismantling

–  Mount gearbox on assembly stand. –  Drain off gear oil. –  Remove clutch release lever and release bearing → Chapter. –  Remove guide sleeve → Chapter.

–  Unbolt gearbox housing cover -arrow-.

–  Remove 5th gear selector fork -arrow-

–  Remove bolts -A- for synchronising 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 synchronising hub and gear wheel cannot turn. The two bolts can now be loosened.

–  Pull off synchronising hub and 5th speed selector gear, and remove together with needle roller bearing. A - Two-arm puller, e.g. -Kukko 20/10- with hooks -Matra V/170- B - Hexagon bolt M10×20

–  Pull off 5th gear wheel. A - Two-arm puller, e.g. -Kukko 20/10- with hooks -Matra V/170- B - Hexagon bolt M10×20 Procedure: Set up two-arm puller and tighten bolt -arrow-. Heat gear wheel with hot air blower -V.A.G 1416- and pull off using two-arm puller.   Note When pulling off the gear ensure that the claws do not bend outwards, if necessary tighten screw -arrow-. Check 5th gear wheel for damage after removal.

–  Remove flange shaft securing bolt. To do this, screw two bolts into flange and counterhold flange shaft with tyre iron or other suitable lever. –  Take out flange shafts together with springs, thrust washers and tapered rings.

–  Remove both bolts -arrows- for reverse shaft support.

–  Remove selector shaft with selector mechanism cover. To do this, set selector shaft in neutral position. Then remove bolts -arrows- and pull selector shaft out of gearbox housing.

–  Remove cover plate -A- and pivot pins -B- from underside of gearbox.

–  Remove pivot pins -A- on top side of gearbox and bolts -B- securing gearbox housing to clutch housing (near differential).

–  Remove bolts -A- securing gearbox housing from inside clutch housing.   Note Do not remove nuts -B- for output shaft bearing mounting.

–  Take off gearbox housing, if necessary carefully lever up all round and alternating between sides on the protruding housing flanges -arrows-, taking care not to damage sealing surfaces.

–  Remove selector forks -A- together with selector plates. –  Unscrew bolt for reverse gear selector mechanism -B-.

–  Remove nuts -B- for output shaft bearing mounting.   Note Bolts -A- can be disregarded.

–  Remove reverse gear -A-, input shaft-B- and output shaft -C- one after the other from clutch housing. –  Take out differential. Assembling –  Insert differential.

–  Always renew O-rings -arrows- for output shaft bearing mounting.   Note The illustration only shows 3 of the 4 O-rings. –  Install input shaft, output shaft and reverse shaft together. –  Tighten nuts for output shaft bearing mounting.

–  Clean locking fluid residue from threads for bolts -a- and -b- in reverse shaft support -arrow-. The threads can be cleaned with a thread tap. –  Install reverse shaft support. –  Install reverse gear selector mechanism.

Installation position: reverse gear –  Install selector forks together with selector plates.

–  Screw M8 x 100 mm stud -A- into reverse shaft support so that support is aligned after fitting gearbox housing. –  Align selector plates.   Note The detent segments must be positioned in the grooves on the locking collars. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing. –  Fit gearbox housing. Install bolts for reverse shaft support -arrow- as follows: –  Insert bolt -a-, remove stud and screw in bolt -b- hand-tight.

Tightening sequence: 1 - Bolt -a- 30 Nm 2 - Bolt -b- 30 Nm

–  Install pivot pins -arrow- for selector forks. To do this align selector mechanism using a screwdriver so that the relevant pivot pin can be inserted. –  Fit cover plate for selector shaft.

Install selector shaft as follows: –  Set selector plates in neutral position. –  Locate lug -arrow 1- in recess in gearbox housing. Position selector shaft so that selector finger -arrow 2- is engaged in selector plates. –  Install selector shaft cover.

Installation position of 5th gear wheel The groove running round the gear wheel -arrow- faces to the gearbox housing.

–  Drive on 5th gear wheel.

–  Attach support bridge -30-211A- with thrust piece -T10030/4-. –  Bring thrust piece -32 - 111- into contact with input shaft by turning bolt, and tighten lock nut -A-. Checking 5th gear synchro-ring

–  Before re-installing selector gear and synchro-ring for 5th gear, press the synchro-ring onto the tapered seat of the selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Specification	Wear limit
5th gear	1.1 ... 1.7 mm	0.5 mm

–  Install 5th speed selector gear with needle bearing. –  Fit 5th gear synchro-ring on selector gear. –  Assemble 5th gear synchronising hub/locking collar before installing → Fig..

Installation position of 5th gear synchronising hub/locking collar The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchronising hub -arrow 2- face the gearbox housing. Retainers in synchronising hub -arrow 3- align with cast locking pieces on synchro-ring ( → ).

5th gear synchro-ring with cast locking pieces -arrows-

–  Knock on 5th gear synchronising hub.   Note When driving on, ensure clearance for synchro-ring. –  Screw in securing bolts for synchronising hub and 5th gear wheel.

Installation position of dished springs for securing bolts for 5th gear wheel and synchronising hub The outer diameter (concave side -arrows-) faces 5th gear.

–  Secure bolts -A- for 5th gear synchronising hub and gear wheel, to do this select 5th gear -arrow 1- and 1st gear -arrows 2- and -3-.

–  After engaging both gears the input shaft and output shaft are locked; the synchronising hub and gear wheel cannot turn. The two bolts -arrows- can now be tightened. –  Install 5th gear selector fork.

Adjusting 5th gear –  Engage 5th gear. Loosen bolt -1-. Press locking collar and selector jaws in direction of -arrow-, then tighten bolt -1- to 25 Nm. l  Check adjustment: It should not be possible to slide a 0.2 mm feeler gauge between locking collar and selector gear. Repeat adjustment if necessary. –  Disengage 5th gear. Locking collar should now be in the neutral position. Synchro-ring should move freely. –  Select all gears. –  Install gearbox housing cover.

–  Pack space between sealing lip and dust lip of oil seals for flange shafts half-full with sealing grease -G 052 128 A1--arrow-.

–  Install both flange shafts with springs, thrust washers and tapered rings. –  Install release bearing guide sleeve → Chapter. –  Install clutch release lever and release bearing → Chapter.