Audi Workshop Service and Repair Manuals

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

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Support bridge -30 - 211 A-

t	Fitting tool -3367/2-

t	Spindle -3291-

t	Box wrench -3059-

t	Press tool -VW 434-

t	Puller -3042-

t	Thrust piece -3002-

t	Thrust plate -VW 447 H-

t	Drift sleeve -VW 244 B-

t	Installing sleeve -VW 455-

t	Drive flange installing tool -VW 391-

t	Extension -30 - 23-

t	Drift sleeve -40 - 20-

t	Fitting tool -3097-

t	Torque wrench -V.A.G 1331-

t	-1-Two-arm puller -Kukko 20/10-

t	-2-Matra hooks -V/170-

t	-2-Puller hook -Kukko 1-250-

t  Installing ring -2003/3- Dismantling –  Drain off gear oil.

–  Mount gearbox on assembly stand.

–  Pull clutch push rod -A- out of input shaft.

–  Attach support bridge -30 - 211 A- for input shaft. A -  Lock nut M12 –  Bring fitting tool -3367/2- into contact with input shaft by turning bolt, and tighten lock nut -A-.

–  Pierce sealing cap -arrow 1- and lever out of gearbox housing cover. –  Unbolt gearbox housing cover -arrow 2- (6 bolts).   Note One of the 6 bolts is inside the cover.

–  Remove speedometer drive -B-. Up to gearbox build date 02 08 8 –  Remove locking bolt for selector shaft -A- with reversing light switch -F4--arrow-.

From gearbox build date 03 08 8 onwards –  Remove locking bolt for selector shaft -2-. –  Remove reversing light switch -F4--1-. Continued for all gearboxes

–  Unscrew selector shaft sealing cap and remove together with spring. –  Set selector shaft to neutral and pull out of gearbox housing.

–  Remove Torx bolt -arrow- securing reverse gear shaft.

–  Remove both flange shafts. –  Take out flange shafts together with springs, thrust washers and tapered rings.

–  Engage 5th gear -arrow 1-. –  Engage reverse gear -arrow 2- (forward selector jaw facing downwards).

–  Remove bolt for synchronising hub -arrow- using 12 mm multi-point bit.

–  Prise free locking plate for selector tube.

–  Unscrew selector tube from selector fork (anti-clockwise).   Note Do not pull selector rod out of selector tube.

–  Remove synchronising hub complete with selector gear and selector fork for 5th gear. If necessary, loosen slightly with 2 levers but take care not to damage sealing surfaces of housing. –  Note thrust washer for selector gear below synchronising hub.

–  Take off circlip and thrust washer -A- for 5th gear wheel.

–  Pull off 5th gear wheel. A -  Two-arm puller, e.g. -Kukko 20/10- with hook -Matra V/170-

–  Unbolt tensioning plate (support for input shaft ball bearing) -arrows-. –  Remove bolts securing gearbox housing to clutch housing.

–  Use bolt (M8) -arrow- to secure drive flange installing tool -VW 391- to gearbox housing. If necessary, remove dowel sleeve first. –  Secure puller -3042- as shown in illustration. l  Fit spindle of puller precisely into bore in input shaft. –  Pull off gearbox housing.

–  Pull selector rod -A- out of bore in clutch housing and swing out selector forks -B-. –  Remove circlip for 4th gear wheel/output shaft.

–  Pull off 4th gear wheel. A -  Two-arm puller, e.g. -Kukko 20/10- with hook -Matra V/170-

–  Take out complete input shaft -A-.   Note Reverse gear -B- must not be engaged.

–  Take off circlip -A- on 3rd gear wheel.

–  Press off 3rd gear wheel via 2nd speed selector gear. A -  Two-arm puller, e.g. -Kukko 20/10- with 250 mm long hooks –  Take off synchro-ring and needle bearing. –  Drive out reverse gear shaft using a plastic hammer after screwing in bolt -arrow-. –  Take reverse gear wheel out of reverse lever.

–  Remove synchronising hub/locking collar and 1st speed selector gear together with 2nd gear needle roller bearing inner race. A -  Two-arm puller, e.g. -Kukko 20/10- with 250 mm long hooks

–  Unbolt bearing mounting -arrows- and take out output shaft. Note thrust washer -1-. –  Take out differential.   Note Make sure rivets on differential are seated tightly. If riveted fastenings are loose, the repair kit (connection final drive gear to differential cage) must be fitted → Item. Assembling –  Insert differential. –  Insert output shaft. –  Tighten bolts for output shaft bearing mounting.

–  Installation position of thrust washer for 1st speed selector gear needle bearing:    Shoulder -A- on inner diameter faces towards bearing mounting -B-. –  Fit thrust washer, needle bearing, selector gear and synchro-ring for 1st gear.

–  Installation position of 1st/2nd gear locking collar/synchronising hub:    The identification groove on face -A- and the outer splines of locking collar -B- face towards 1st speed selector gear -C-.

–  Heat 1st/2nd gear locking collar/synchronising hub to approx. 100 °C, fit and drive onto stop.    Turn synchro-ring so that grooves align with locking pieces. –  Install reverse gear wheel, drive in shaft if necessary.

–  Drive on needle bearing inner race for 2nd speed selector gear as far as stop. –  Fit needle bearing, synchro-ring, 2nd speed selector gear and 3rd gear wheel.

Installation position of 3rd gear wheel Collar -arrow- towards 2nd speed selector gear -A-. –  Use drift sleeve -VW 244 B- to drive on 3rd gear wheel as far as stop.

Adjust axial play of 3rd gear wheel as follows: –  Determine thickest circlip which will still just fit and install.

Thickness (mm)	Identification
2.5	Brown
2.6	Black
2.7	Bright metal
2.8	Copper
2.9	Brass
3.0	Blue

Part No of circlips → Electronics parts catalogue.

–  Attach support bridge -30 - 211 A- for input shaft.   Note In cases where input shaft has not been dismantled: Press off input shaft grooved ball bearing → Item. –  Fit complete input shaft but without grooved ball bearing. A -  Lock nut M12 –  Bring fitting tool -3367/2- into contact with input shaft by turning bolt, and tighten lock nut -A-.

Installation position of 4th gear wheel Collar -arrow- faces towards 5th gear splines -A-. –  Fit 4th gear wheel on output shaft using extension -30 - 23- and secure with circlip.

–  Press on input shaft grooved ball bearing. Installation position: Wider collar on inner race -arrow- faces towards press tools.

–  Secure tensioning plate -arrow-.   Note The tensioning plate can only be fitted in one position.

–  Insert lower spring -arrow- for selector rod into clutch housing.

–  Install selector fork set and align selector jaws. A -  1st/2nd gear selector fork -arrow- faces towards recess for selector bridge -C- B -  3rd/4th gear selector fork C -  Selector bridge with selector tube for 5th gear D -  Reverse gear selector fork –  Insert selector rod.

–  Align reverse gear shaft. Distances -x- are equal. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing.

–  Drive on gearbox housing. –  Secure reverse gear shaft. –  Tighten hexagon bolts for securing gearbox housing to specified torque. –  Re-tighten oval-head countersunk bolts on tensioning plate for grooved ball bearing to 15 Nm. –  Drive on 5th gear wheel.

Installation position: Groove -arrow- faces upwards. –  Install thrust washer and circlip. –  Fit 5th gear synchronising hub complete with locking collar, 5th speed selector gear and selector fork and new securing plate. –  Use box wrench -3059- to screw selector tube clockwise into selector fork.

–  Unscrew selector tube until it projects by -x- = 5.0 mm.   Note Do not pull the selector rod out of the selector tube (this may happen if the box spanner is tilted), otherwise the selector forks in the gearbox will fall apart and the gearbox will have to be dismantled again. If necessary, hold the selector rod down with a screwdriver inserted through the side slot when taking off the box spanner. –  Position new bolt for synchronising hub together with dished spring. l  The thread of the new bolt should already be coated with locking fluid If necessary, coat bolt with locking fluid -D 000 600 A2-. l  Installation position of dished spring: the outer diameter (concave side) faces 5th gear.

–  Engage 5th gear -arrow 1-. –  Engage reverse gear -arrow 2- (forward selector jaw facing downwards). –  Tighten bolt for synchronising hub with 12 mm multi-point bit. –  Set selector forks in neutral position.

–  Carefully insert selector shaft -1- to make sure the selector shaft oil seal is not damaged. If necessary, slide shrink hose onto splines of selector shaft. –  Insert spring -2- for selector shaft and secure sealing cap -3- with new O-ring -4-. Up to gearbox build date 02 08 8 –  Apply sealant -AMV 188 200 03- and insert locking bolt for selector shaft/reversing light switch -F4--5-.

From gearbox build date 03 08 8 onwards –  Install reversing light switch -F4--1-. –  Apply sealant -AMV 188 200 03- to locking bolt -2- for selector shaft and fit bolt. Continued for all gearboxes Adjust 5th gear selector fork as follows: l  Perform this adjustment with great care to avoid any risk of the gearbox “jumping out of gear”.

–  Check projection of selector tube - dimension -x- = 5.0 mm; adjust with box wrench -3059-, if necessary. –  Bolt gearbox selector lever to selector shaft and engage 5th gear (pull selector shaft fully out and turn to the left).

–  Align locking collar -1- with selector fork -2- so there is no free play at 5th speed selector gear -3-. l  Check measurement: The distance -a- between locking collar and selector gear must be 1.3 mm. Adjust this distance if necessary by turning the selector tube. –  Disengage 5th gear. Locking collar should now be in the neutral position. Synchro-ring should move freely.

–  Drive on new locking plate. Use suitable tools with a thickness of approx. 12 mm to support selector fork, e.g. two flat open-end spanners -A- (19 mm and 24 mm). –  Select all gears. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of gearbox housing.

–  Fit gearbox housing cover -arrow- (6 bolts).   Note One of the 6 bolts is inside the cover.

–  Then insert release bearing -A- into gearbox housing cover.

–  Drive on sealing cap -A- using installing ring -2003/3-.   Note Sealing surface on gearbox housing cover must be free of grease.

–  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. –  Remove support bridge -30 - 211 A- for input shaft.

–  Guide clutch push rod -A- into input shaft.