Audi Workshop Service and Repair Manuals

Servicing gearbox cover

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Thrust ring -2006 A-

t	Locking pin -2064-

t	Thrust pad -3062-

t	Assembly tool -3253-

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

t	-1-Internal puller -Kukko 21/4-

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

t	Depth gauge

t

Stud M10

1 -	Gearbox cover

2 -

Dowel pin

q

2 x

q	Insert in gearbox cover

q	Drive in until flush with rear surface of housing flange

3 -	Needle bearing

q	Bearing for hollow shaft in gearbox cover

q	Pressing out → Fig.

q	Pressing in → Fig.

q	Peen to secure after installing → Fig.

4 -	Ball sleeve

q	For reverse gear selector rod

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Measuring installation depth → Fig.

5 -	Ball sleeve

q	For selector rod for 1st and 2nd gear

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Measuring installation depth → Fig.

6 -	Roller bearing

q	Bearing for input shaft in gearbox cover

q	Always renew

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Peen to secure after installing → Fig.

Pressing needle bearing out of gearbox cover –  Eliminate peening depressions if necessary.

Pressing needle bearing into gearbox cover Install needle bearing so the lettering (side with thicker metal) faces towards the thrust pad -3062-. –  Press in needle bearing to installation depth = 262 ± 0.5 mm, measured from housing flange to needle bearing (similar to illustration A34-10190 → Fig.). –  Secure needle bearing after pressing in by peening into gearbox cover → Fig..

Pulling out ball sleeve from gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 14.5...18.5 mm, e.g. -Kukko 21/2- C -  Stud M10   Note Adapter -VW 771/44- can also be used instead of stud M10 and -VW 771/15-.

Pressing ball sleeve into gearbox cover –  Fit ball sleeve so that side with lettering (thicker metal) faces locking pin -2064-. Fit the small Ø of locking pin -2064- in the ball sleeve. –  Support gearbox cover below bearing seat using thrust ring -2006 A-. Installation depth of ball sleeve → Fig..

Installation depth of ball sleeve in gearbox cover –  Press in ball sleeve for reverse gear selector rod -1- and for 1st/2nd gear selector rod -2- to dimension -a- = 250.5 ± 0.5 mm.

Pulling out roller bearing from gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 30...37 mm, e.g. -Kukko 21/4- –  Eliminate peening depressions if necessary.   Note Always renew roller bearing after pulling out.

Carefully press in new roller bearing into gearbox cover until limit stop. Support gearbox cover below bearing seat using thrust ring -2006 A-. –  Secure roller bearing after pressing in by peening into gearbox cover → Fig..

Securing needle bearing and roller bearing in gearbox cover by peening. –  Use a blunt punch with a ball shaped end (ball Ø approx. 5 mm) to peen in position. –  Needle bearing -1- and roller bearing -2- are secured with 3 peening positions each which are offset by 120° -arrows A- and -arrows B-. Observe position and Ø of peening positions: t  Dimension -a- = 2 mm t  Dimension -b- = 3 mm