Audi Workshop Service and Repair Manuals

Servicing gearbox housing

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Tube -VW 423-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Guide pin -10 - 15-

t	Drift sleeve -30 - 100-

t	Tube -32 - 109-

t	Locking pin -2064-

t	Assembly tool -3253-

t	Internal puller -3275-

t	-1-Internal puller -Kukko 21/2-

t	-4-Counter-support -Kukko 22/1-

t	-4-Counter-support -Kukko 22/2-

t	Depth gauge

t  Straightedge -T 40100-

1 -	Needle bearing

q	For input shaft

q	Always renew

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

q	Peen to secure after installing → Fig.

2 -	Ball sleeve

q	For selector shaft

q	Pulling out → Fig.

q	Driving in and securing → Fig.

3 -

Cap

q	For gearbox breather

4 -	Breather pipe

q	Installation depth → Fig.

q	Clip in cap → Item for gearbox breather

5 -	Gearbox housing

q	When renewing: re-determine positioning of 2nd speed selector gear → Chapter, adjust pinion shaft and differential (final drive gear set) → Chapter

6 -	Ball sleeve

q	For selector shaft

q	Pulling out → Fig.

q	Driving in → Fig.

7 -	Oil seal for selector shaft

q	Can be renewed with gearbox removed (gearbox remains assembled) → Chapter

q	Always renew

q	Pulling out → Fig.

q	Driving in → Fig.

q	Always use assembly sleeve to fit oil seal (if selector shaft remains installed in gearbox) → Chapter

8 -	Tapered roller bearing outer race (right-side)

q	For differential

q	If renewed: adjust differential (crown wheel) → Chapter

q	Removing and installing → Item

9 -

Shim “S2”

q	Note thickness

q	Table of adjustments → Chapter

10 -	Grooved ball bearing

q	For input shaft

q	Removing (gearbox dismantled) → Fig.

q	Removing (gearbox removed but not dismantled) → Chapter

q	Installing → Fig.

11 -	Intermediate piece

q	Renew if damaged

12 -	Oil drain plug, 40 Nm

13 -

Oil seal

q	For flange shaft (right-side)

q	Renewing → Chapter

14 -

Magnet

q

Clean

q	Insert in gearbox housing rib

15 -	Ball sleeve

q	For reverse gear selector rod

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

16 -	Ball sleeve

q	For selector rod for 1st and 2nd gear

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

17 -	Ball sleeve

q	For selector rod for 3rd and 4th gear

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

18 -	Ball sleeve

q	For selector rod for 5th and 6th gear

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

Pulling out input shaft needle bearing from gearbox housing A -  Counter-support, e.g. -Kukko 22/2- –  Eliminate peening depressions if necessary.

Driving input shaft needle bearing into gearbox housing Install needle bearing so the lettering (side with thicker metal) faces towards the drift sleeve -30 - 100-. Insertion depth of needle bearing → Fig..

Measuring insertion depth of needle bearing and peening needle bearing l  Dimension for pressing in -a- = 88.0 ± 0.5 mm –  Use a blunt punch with a ball shaped end (ball Ø approx. 5 mm) to peen in position. –  The needle bearing is secured with 3 peening positions offset by 120° -arrows-.

Removing selector shaft ball sleeve A -  Internal puller 14.5...18.5 mm, e.g. -Kukko 21/2- –  Eliminate peening depressions if necessary.

Driving in ball sleeve for selector shaft and securing by peening Fit ball sleeve so that side with lettering (thicker metal) faces guide pin -10 - 15-. –  Drive in ball sleeve -1- to depth -a- = 1.5 ± 0.5 mm below surface of housing. Perform the following procedure to secure by peening after driving in: –  Use a blunt punch with a ball shaped end to peen ball sleeve in position. –  The ball sleeve is secured with 3 peening positions -b- offset by 120°.

Installation dimension of breather pipe Dimension -a- = 16.8 mm

Pulling out oil seal for selector shaft with gearbox dismantled –  Lever out oil seal carefully with a screwdriver.

Removing selector shaft ball sleeve First remove selector shaft oil seal → Fig.. A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 14.5...18.5 mm, e.g. -Kukko 21/2-

Driving in ball sleeve for selector shaft l  Insertion depth: 8.5 ± 0.5 mm below surface of housing.

Driving in oil seal for selector shaft –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of oil seal. –  Knock in new oil seal -arrow- to a depth of 1.0 ± 0.2 mm below surface of housing; keep seal straight when installing.

Removing grooved ball bearing for input shaft when gearbox is dismantled –  Fit smaller diameter of adapter -VW 295 A- into grooved ball bearing. –  Drive out grooved ball bearing.

Driving in grooved ball bearing for input shaft as far as stop Installation position: The sealed side of the ball cage faces the gearbox housing. –  Drive grooved ball bearing onto stop in gearbox housing.

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

Driving in ball sleeve for selector rod –  Drive in ball sleeve -A- for 5th and 6th speed selector rod to installation depth → Fig. using locking pin -2064-. –  Drive in remaining three ball sleeves -B- to installation depth → Fig. using guide pin -10 - 15-. Fit ball sleeve so that side with lettering (thicker metal) faces guide pin -10 - 15- or locking pin -2064-.

Insertion depth of ball sleeves in gearbox housing –  Press in ball sleeve for 5th/6th gear selector rod -1- to dimension -a- = 143.5 ± 0.5 mm. –  Press in ball sleeve for 3rd/4th gear selector rod -2- to dimension -a- = 133.5 ± 0.5 mm. –  Press in ball sleeve for 1st/2nd gear selector rod -3- to dimension -a- = 116.5 ± 0.5 mm. –  Press in ball sleeve for reverse gear selector rod -4- to dimension -a- = 116.5 ± 0.5 mm.   Note Measure distance between surface of housing to respective ball sleeve using depth gauge.