Audi Workshop Service and Repair Manuals

Removing and installing input shaft, output shaft (pinion shaft), differential, selector mechanism and selector forks

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 422-

t	Guide pin -T10079-

t	Thrust piece -T10080-

t	Thrust piece -T10081-

t	Thrust block -T10083-

t	Thrust plate -T10084 A-

t	Thrust piece -T10085-

t  Used oil collection and extraction unit -V.A.G 1782-

Removing l  Gearbox removed –  Mount gearbox on assembly stand → Chapter. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Drain off gear oil. –  Remove left flange shaft securing bolt; to do so, screw two bolts into flange and counterhold flange shaft with tyre iron or other suitable lever. –  Pull out flange shaft together with spring, thrust washer and tapered ring.

–  Unbolt gearbox housing cover -arrow-.

–  Pull out pivot pin -1- for 5th gear selector fork -2- and remove selector fork. –  Remove circlip -3- for 5th gear synchronising hub. –  Remove circlip -4- for 5th gear wheel. –  Take off selector gear, locking collar with synchronising hub, and gear wheel.

–  Unscrew securing bolts -A- for bearing mounting for input and output shafts. –  Unscrew hexagon flange nut -B- for selector mechanism (reverse gear wheel mounting). –  Turn gearbox on assembly stand so that clutch housing faces upwards.

–  Remove right flange shaft securing bolt; to do so, screw two bolts into flange and counterhold flange shaft with tyre iron or other suitable lever. –  Pull out flange shaft together with spring, thrust washer and tapered ring.

–  Unhook spring -arrow- from clutch release lever. –  Remove bolts -1- and -2-. –  Remove release lever with release bearing and guide sleeve.

–  Remove all 18 bolts -arrow- securing clutch housing. –  Carefully remove clutch housing by levering alternately at the protruding webs on the housing, taking care not to damage the sealing surfaces.

–  Remove differential -A- from gearbox housing.

–  Remove selector shaft with selector mechanism cover -A-. For this purpose, bring selector shaft into the neutral position. Then remove bolts -arrows- and pull selector mechanism cover and selector shaft out of gearbox housing. –  Remove pivot pins -B- from top of gearbox. –  Remove reversing light switch -C-.

–  Remove bolt -A- securing reverse gear shaft. –  Remove pivot pins -B- from gearbox underside.   Note Do not remove cover plate -arrow- when dismantling gearbox.

–  Press out input and output shafts together with bearing mounting, selector mechanism (selector forks) and reverse gear wheel.   Note t  Place gearbox housing on thrust plates -VW 401- and -VW 402- so that the dowel sleeves in the gearbox housing do not become damaged. t  Make sure components do not drop out when being removed (get help from a second person if necessary).

–  Slide locking collar for 1st and 2nd gear onto 2nd gear. –  Slide in thrust plate -T10084 A- sideways until it contacts input shaft. –  Insert centralising pins in thrust piece -T10081- into bores in input and output shafts.   Note Make sure components do not drop out when being removed (get help from a second person if necessary). –  Press input and output shafts out of bearing mounting. –  Take out bearing mounting. –  Dismantle input shaft if necessary → Chapter. –  Dismantle output shaft if necessary → Chapter.

Installing Tightening torques → Chapter, → Chapter, → Chapter   Note The bearing mounting must always be renewed if it is separated from the gearbox housing.   WARNING Wear protective gloves. –  Heat bearing mounting to about 100°C –  Press on bearing mounting with grooved ball bearings.

–  Press on sleeve -A- for 5th gear needle bearing.

–  Place the pre-assembled input shaft -2- and output shaft -1- with bearing mounting for grooved ball bearings in thrust piece -T10085-. –  Screw guide pin -T10079- onto threaded pin (reverse gear mounting) -arrow-. –  Insert selector mechanism (selector forks) -4- in locking collars on shafts. –  Fit reverse gear shaft -3- with reverse gear wheel.

–  Insert assembled components into gearbox housing, running guide pin -T10079- into gearbox housing through hole for selector mechanism mounting. –  Unscrew guide pin -T10079-. –  Check that selector forks engage correctly in locking collars before pressing in bearing mounting.

–  Carefully press in bearing mounting together with input and output shafts as far as the stop. –  Secure bearing mounting lightly with bolt tightened finger-tight.

–  Screw in bolt -A- for reverse gear shaft. –  Install pivot pins -B- on underside of gearbox.

–  Screw in reversing light switch -C-. –  Align selector mechanism and install pivot pins -B- on top of gearbox. –  Set selector plates in neutral position. –  Clean sealing surfaces; they must be free from oil and grease. –  Apply sealing paste -AMV 188 200 03- evenly to sealing surface. –  Install selector shaft with selector mechanism cover -A-. Then tighten bolts -arrows-.

–  Using new bolts -A-, secure bearing mounting for input and output shafts.   Note Tighten the bolts in stages to the specified torque in diagonal sequence, starting in the centre. –  Tighten hexagon flange nut -B- for selector mechanism (selector forks). –  Engage all gears to check function.

–  Install differential -A-. –  Clean sealing surfaces; they must be free from oil and grease. –  Apply sealing paste -AMV 188 200 03- evenly to sealing surface. –  When installing housing, rotate input shaft by hand to enable bearing to slide easily onto its seat.

–  Tighten gearbox housing bolts -arrow- diagonally in stages. –  Turn gearbox on assembly stand so that gearbox housing faces upwards.

–  Fit 5th gear wheel -1-. l  Installation position of 5th gear wheel: the large collar -arrow- points to the gearbox housing cover.

–  Install the following components in the sequence indicated: 1 -  Needle bearing for 5th speed selector gear 2 -  5th speed selector gear 3 -  5th gear synchro-ring 4 -  5th gear synchronising hub with locking collar and check ring

–  Fit 5th gear selector fork -2- and slide pivot pin -1- in onto stop in direction of -arrow-. –  Determine thickness of new circlips -arrow- for input shaft -3- and output shaft -4-. –  Determine the thickest circlip that will just fit and install it. For Part No. refer to → Electronic parts catalogue. The following circlips are available:

Circlip thickness (mm)
2.00	2.10	2.20

–  Install gearbox housing cover.

–  Install both flange shafts with springs, thrust washers and tapered rings (press in towards gearbox housing and tighten bolts). –  Install clutch release lever together with release bearing and guide sleeve → Chapter. –  Fill up oil in gearbox and check oil level → Chapter. Tightening torques → Chapter, → Chapter, → Chapter