Audi Workshop Service and Repair Manuals

Dismantling gearbox –  Place container under gearbox. –  Drain gear oil.

–  Secure gearbox to assembly stand with bolts -arrows-. –  Turn gearbox in assembly stand so that it is in horizontal position.

–  Slacken off bolt -1- and remove leaf spring -2-. –  Remove clutch release lever -3- with release bearing.

–  Unscrew bolts -arrows- and remove retaining piece -1-. –  Pull guide sleeve -2- out of gearbox housing. –  Remove intermediate piece -3- from gearbox housing.

–  Lever off O-ring -arrow- using a small screwdriver.

–  Then remove circlip -arrow- in front of grooved ball bearing for input shaft.   Note t  It is not necessary to remove the grooved ball bearing for input shaft to dismantle the gearbox. t  A defective input shaft bearing can be renewed with gearbox removed (gearbox remains assembled); the required procedure is described on → Chapter. –  Put selector shaft in neutral position.

–  Pull out the two locking bushes -A- for selector shaft.   Note t  Mark the locking bushes to make sure that they are not interchanged with the locking bushes for the selector rods. t  The locking bushes were modified shortly after start of production → Fig.. –  Remove bolts -arrows- and take off selector shaft cover -B-.

–  Push selector shaft -A- into gearbox as far as it will go, simultaneously removing pin -B-. –  Pull out selector shaft.

–  Unscrew bolts -arrows- and detach Torsen housing. –  Remove Torsen differential from pinion shaft/hollow shaft.

–  Remove circlip -1- and shim(s) -2- from pinion shaft.   Note Note down thickness of circlip and shim(s). –  Remove inner race -3- and outer race -4-. These components are a push fit and can be removed by hand. –  Remove spacer ring -5- from 12-point nut on hollow shaft.

–  Lock hollow shaft in position by moving selector rods -1- to -4- in direction of -arrow-.

–  Now slacken 12-point nut on hollow shaft using socket -T40097-. A -  Torque wrench –  Set selector rods to neutral position. –  Then turn the gearbox in the assembly stand so that the gearbox cover faces upwards.

–  Unscrew bolts -arrows 1- (securing bearing mounting), bolt -arrow 2- (securing reverse shaft) and bolts -A- securing gearbox cover to gearbox housing.   Note Always renew O-ring -C-.

–  Remove reverse gear wheel -1- and reverse shaft. –  Detach clutch unit -2- with reverse gear synchro-rings by hand. Remove magnet -3- from gearbox housing.

–  Remove locking bushes -1- to -4- for selector rods.

–  Remove locking collar -A- with selector fork -B- and reverse selector gear -C-. –  Detach thrust washer for reverse and 1st speed selector gears. –  Remove 1st speed selector gear with needle bearing and synchro-rings.

–  Detach 2nd speed selector gear -C- together with inner ring for 1st speed selector gear -D- and 1st/2nd speed selector fork -B- from hollow shaft. A -  Two-arm puller, e.g. -Kukko 20/10- with puller hook, length 250 mm

–  Remove bearing mounting -A- with mounting for reverse shaft -B-. –  Pull oil guide panel -C- out of gearbox housing.

–  Then guide hollow shaft -1- together with input shaft -2- and selector rods -3- and -4- upwards and over pinion shaft -arrow-.

–  Remove bolts -arrows- and detach retaining plate -A- and shim “S4” located below retaining plate.

–  Carefully pull pinion shaft -1- out of opening in gearbox housing -2-. Take care not to pull apart the outer races -3- and -4- of the double angular contact ball bearing, otherwise the seal -6- of the double angular contact ball bearing can be damaged by the pinion gear -5-.If this should happen, the double angular contact ball bearing must be renewed.