Audi Workshop Service and Repair Manuals

Servicing gearbox housing

Special tools and workshop equipment required

t	Guide pin -VW 436A-

t	Guide pin -VW 439-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Guide pin -10-15-

t	Thrust piece -3124-

t	Drift sleeve -VW 244B-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Tube -VW 416 B-

t	Punch -3264-

t	Assembly tool -3290-

t	Drift -T10168-

t	Drift -T10169-

t	Thrust piece -T10203-

t	-1- Kukko internal puller 21/2 and 21/4

t	-4- Kukko 22/2 counter-support

t	Thread adapter from counter-support Kukko 22/1

t  Drift -T10362-

Removing sealing cap -A- –  Pierce rubber in centre of sealing cap with a screwdriver -B- and pry off sealing cap -in direction of arrow-.

Driving in sealing cap –  Drive in sealing cap as far as stop.

Removing angled rod for selector shaft –  Shear off pin in released position. –  Insert screwdriver -A- in bore for angled rod -B-. –  Pry out angled rod -arrow-.

Installation position of angled rod l  Marking on angled rod -arrow- must face towards connection on slave cylinder -1-. l  Angle -a- must be approx. 45°.

Driving in angled rod for selector shaft l  The angled rod -arrow- must be in the released position when driving in. –  Drive in angled rod until tool contacts stop.

Pulling out bearing bush for selector rod A -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2- B -  Counter-support, e.g. -Kukko 22/2-

Driving in selector rod bush –  Drive in selector rod bush until tool contacts stop.

Pressing out stop sleeve (gearbox dismantled) –  Place gearbox housing on thrust plates -VW 401- and -VW 402- so that the dowel sleeves in the gearbox housing do not become damaged. –  Press out stop sleeve -A-.

Driving out stop sleeve (gearbox not dismantled) l  Locking bolt and selector shaft removed –  Turn gearbox so that stop sleeve does not drop into gearbox. –  Drive out stop sleeve using guide pin -10-15-.

Different versions of stop sleeve –  A stop sleeve with shoulder -arrow 1- → Fig. or without shoulder -arrow 2- → Fig. may be fitted. For correct version, refer to → Electronic parts catalogue.

Driving in stop sleeve with shoulder as far as tool stop l  Gearbox housing bolted to clutch housing

Driving in stop sleeve without shoulder as far as tool stop l  Gearbox housing bolted to clutch housing

Pulling needle bearing for reverse shaft out of gearbox housing A -  Internal puller 23.5 ... 30 mm, e.g. -Kukko 21/4- B -  Counter-support, e.g. -Kukko 22/2-   Note The needle bearing is destroyed during removal and must be renewed.

Pressing needle bearing into gearbox housing –  Before pressing in, place reverse shaft thrust washer -B- on needle bearing -A-. –  Place tube -VW 416 B- directly under bearing mounting to support gearbox housing.

Pulling out selector shaft bush –  Use thread adapter from counter-support Kukko 22/1 -arrow-. –  Hold spindle of assembly tool -3290- tight and turn nut -B-. A -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2-

Driving in selector shaft bearing bush –  Drive in bearing bush -A- until tool contacts stop.

Driving out plug –  Drive out plug -1- from inside of gearbox housing -arrow-.

Driving in plug –  Drive in plug -1- using punch -3264- to a depth of approx. 3 mm (distance -a- below surface of housing).