Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Thrust plate VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 412
• ◆ Tubular section VW 415 A
• ◆ Thrust pad VW 447 H
• ◆ Thrust pad VW 454

• ◆ Engine and gearbox holder VW 540
• ◆ Pressing-out lever VW 681
• ◆ Multi-purpose tool VW 771
• ◆ Attachment 30-23
• ◆ Fitting sleeve 30-100
• ◆ Support bridge 30-211 A

• ◆ Fitting sleeve 40-21
• ◆ Mandrel 2064
• ◆ Clamping sleeve 3116
• ◆ Thrust pad 3118
• ◆ Drift 3121
• ◆ Internal puller 3275

• ◆ Pressing tool 3276

• ◆ 1 - Two-arm puller Kukko 20/10
• ◆ 2 -Hook Matra V/170
• ◆ Drip tray
• ◆ Depth gauge

Dismantling

• ‒ → Mount gearbox in repair stand VW 540.
• ‒ Place drip tray under gearbox.
• ‒ Drain off gear oil.
• ‒ Remove release bearing, clutch release lever and guide sleeve
  .

• ‒ → Unscrew bearing housing -arrow- and detach.

•     A -    Stud M8/M10

→ On detaching, bearing housing is pressed off end cover slightly by coil spring -A-.

• ‒ Heed installation position of dished washer -C- on detaching bearing housing.
• ‒ Outer diameter (concave side) faces shims
• ‒ Remove shims -B-, note down thickness and re-determine if necessary => Page 34-202.

• ‒ → Pull Torsen differential out of end cover.

• ‒ → Pull oil collector out of end cover -arrow- until it is free to move.

• ‒ → Swivel oil collector -arrow- downwards and guide out through hole of end cover.
• ‒ Remove oil collector.

• ‒ → Remove locking bolts -A- for selector shaft from gearbox housing.
• ‒ Mark fitting location of aluminium/ steel bolts; do not interchange.
• ‒ Screw out 3 bolts -B- for selector shaft cover and remove cover.
• ‒ Pull out selector shaft.

• ‒ → Lock input shaft in position by engaging 2 gears (e.g. reverse and 2nd gear); to do so, shift 2 selector plates -arrows-.

• ‒ → Through hole -arrow A- in end cover, slacken off and screw out multi-point socket-head bolt -arrow B- in input shaft.
• ‒ Slacken off and screw out 2 bolts -arrow C- for end cover for manual gearbox at support plate for needle bearing -arrow D-.
• ‒ Remove support plate.

• ‒ → Remove and clean 2 magnets -arrows A-.
• ‒ Slacken off and screw out 5 bolts -arrows B- securing end cover for manual gearbox.

• ‒ → Remove 2nd input shaft ball bearing inner race from input shaft.

•     A -    Shim

Note:

On extraction, internal puller 3275 engages in all-round groove of inner race -arrow-.

• ‒ Detach end cover with end cover/bearing plate gasket.
• ‒ Extract dowel sleeves from bearing plate.

• ‒ → Detach 5th speed sliding gear with spring together with 1st inner race -A- for ball bearing for input shaft.

•     B -    Two-arm puller, e.g. Kukko 20/10

• ‒ Detach synchro-ring for 5th gear.
• ‒ Detach 5th gear wheel circlip.

• ‒ → Detach 5th gear wheel. To do so, block hollow shaft by engaging 2 gears => Page 34-175.

Note:

Only use hexagon bolt of clamping sleeve 3116, length 50 mm.

•     C -    Two-arm puller, e.g. Kukko 20/10 with 200 mm puller

• ‒ Remove shim -B- for 5th gear wheel, note down thickness and re-determine if necessary => Page 34-194.
• ‒ Detach spacer sleeve -A-.

• ‒ → Press out spring pin -A- for 5th and 6th gear selector fork.

Note:

Do not drive out spring pin as this could damage selector rod mount.

• ‒ Pull selector rod at actuating arm driver together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (resistance is felt).

• ‒ → Mark locking collar for 5th and 6th gear -arrow 1- and synchro-hub -A- (paired) in installation position -arrow 3-.

• ‒ → Pull actuating arm driver together with selector fork and locking collar off selector rod.

• ‒ → Detach 6th speed sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th gear and inner race for 5th speed sliding gear.

•     A -    Two-arm puller, e.g. Kukko 20/10 with 200 mm puller

• ‒ → Unscrew locking bolts for selector rods.

•     A -    1st and 2nd gear
•     B -    3rd and 4th gear
•     C -    5th and 6th gear
•     D -    Reverse gear

• ‒ Mark fitting location of aluminium/ steel bolts; do not interchange.
• ‒ Drive out dowel sleeves at bearing plate and unscrew bearing plate from gearbox housing.
• ‒ Secure drive pinion with respect to hollow shaft to stop it slipping using hose clamp for example.

• ‒ Separate bearing plate with input shaft, drive pinion, hollow shaft and internal selector mechanism from gearbox housing.

• ‒ → Remove circlip from selector rod for 1st and 2nd gear and detach actuating arm driver -A-.
• ‒ Pull out selector rod -B- for 5th and 6th gear.
• ‒ Remove actuating arm driver -C- for reverse gear.

• ‒ → Remove thrust washer -arrow A- for 6th gear needle bearing from shaft.
• ‒ Use offset pliers to remove circlip -arrow B- for cylindrical roller bearing inner race.
• ‒ Take out inner race -arrow C- for cylindrical roller bearing (not fixed).

• ‒ → Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out of bearing plate at an angle.

• ‒ → Screw out hexagon bolt -D-, detach spring clip -B- and retainer -A-and pull out shaft -C- for reverse idler gear.
• ‒ Take out spring, synchro-ring and reverse idler gear.
• ‒ Detach actuating arm for reverse gear.
• ‒ Removing and installing reverse gear => Page 34-234

Notes:

• ◆ Drive pinion and hollow shaft can be removed complete if 6th gear wheel can easily be prised off.
• ◆ If, however, it is necessary to press off 6th gear wheel, drive pinion must be pulled out of hollow shaft.

• ‒ Remove temporary drive pinion securing element (hose clamp).

• ‒ → Pull drive pinion out of hollow shaft -D- and collect taper rollers -A- (23x).
• ‒ Detach corrugated spring -B- and needle ring -C-.

Note:

Take care to avoid bearing contamination and clean if necessary.

• ‒ → Check that bearing is complete.

•     1 -    Collar ring (conical contact surface facing taper rollers)
•     2 -    Taper rollers (23x) with large diameter facing end of drive pinion
•     3 -    Support ring (conical contact surface facing taper rollers)
•     4 -    Corrugated spring
•     5 -    Circlip for drive pinion taper roller bearing

• ‒ → Remove 6th gear wheel.

Note:

Slight pressure may have to be exerted on account of type of fit.

• ‒ Take hollow shaft or drive pinion and hollow shaft with selector rod and selector fork for 1st and 2nd gear out of bearing plate.

Assembly

• ‒ Insert hollow shaft with selector fork and selector rod for 1st and 2nd gear (without actuating arm driver) in bearing plate.
• ‒ → Heat 6th gear wheel to approx. 100 °C and fit.
• ‒ Installation position: Collar facing taper roller bearing

• ‒ Press home such that there is no clearance.
• ‒ Apply multi-purpose grease to drive pinion/hollow shaft taper roller bearings.
• ‒ Layout => Page 34-184

•     A -    → Collar ring, taper rollers (23x) and support ring
•     B -    Corrugated spring
•     C -    Needle ring
•     D -    Hollow shaft

• ‒ Thoroughly lubricate needle bearing.
• ‒ Insert drive pinion in hollow shaft and use hose clamp to stop it slipping out.

• ‒ → Place actuating arm -A- for reverse gear on bolt for actuating arm. In doing so, pay attention to pin (for limiting travel of actuating arm with respect to synchro-ring).
• ‒ Insert sliding gear -B- and engage actuating arm in groove at sliding gear.
• ‒ Fit synchro-ring -C-.
• ‒ Installation position: Align chamfer at periphery of synchro-ring with input shaft (not yet installed) -arrow 1-
• ‒ Insert spring.
• ‒ Installation position: Engage single-offset end in recess at synchro-ring -arrow 2-. Turn double-offset end anti-clockwise and engage in opening at bearing plate -arrow 3-.

• ‒ → Insert shaft -C-.
• ‒ Fit retainer -A-.
• ‒ Installation position: Chamfers of holes for synchro-ring locking pins facing bearing plate
• ‒ Insert spring clip -B- in synchro-ring locking pins.
• ‒ Replace self-locking bolt -D- and tighten to 25 Nm.

• ‒ → Insert input shaft -A- with selector rod and selector fork for 3rd and 4th gear in bearing plate at an angle.
• ‒ Installation position of selector fork: Rib facing actuating arm driver => Page 34-166

• ‒ → Slide inner race -arrow C- for cylindrical roller bearing onto main shaft at flange for end cover (clearance fit).
• ‒ Use offset pliers to fit circlip -arrow B-.

• ‒ → Engage recess in reverse-gear actuating arm driver in free end of actuating arm -arrow A-.
• ‒ Use reverse-gear actuating arm driver to move selector rod for 5th and 6th gear in direction of -arrow B-.

• ‒ → Slide actuating arm driver for 1st and 2nd gear -A- onto selector rod and secure with circlips.
• ‒ Lubricate all bearing points of input shaft and drive pinion/hollow shaft in gearbox housing, as well as bearing flange and selector rods with gear oil.

• ‒ → Use VW 681 to carefully prise old oil seal for input shaft out of gearbox housing.
• ‒ Coat sealing surfaces between bearing plate and gearbox housing with sealing paste AMV 188.000 02.
• ‒ Insert complete bearing plate in gearbox housing.

Note:

On inserting complete bearing plate, make sure selector rods are aligned with bearing points.

• ‒ Fit 2 dowel sleeves for bearing flange/gearbox housing.
• ‒ Diagonally tighten 12 bolts.

• ‒ → Coat locking bolts for selector rods with sealing paste AMV 188 001 02 and screw in.

•     A -    1st and 2nd gear
•     B -    3rd and 4th gear
•     C -    5th and 6th gear
•     D -    Reverse gear

• ‒ Do not interchange aluminium/ steel bolts.
• ‒ Tightening torque:
  Aluminium locking bolt 50 Nm
  Steel locking bolt 70 Nm

• ‒ → Fit thrust washer -arrow A- for 6th gear needle bearing.
• ‒ Installation position: Collar facing circlip -arrow B-, smooth thrust surface facing shaft end
• ‒ Lubricate needle bearing for 6th speed sliding gear with gear oil and place in position.
• ‒ Fit 6th speed sliding gear with spring and synchro-ring.
• ‒ Installation position of synchro-ring: Lugs of synchro-ring engage in recesses of sliding gear below

• ‒ → Support input shaft with bridge 30-211 A.

→ Installation position of synchro-hub for 5th and 6th gear:

• ◆ Projecting end face -arrow 1- facing shaft end
• ◆ Oil drilling of input shaft -arrow 2- and oil groove of synchro-hub
  -arrow 3- in alignment

• ‒ → Heat synchro-hub for 5th and 6th gear to approx. 100 °C, place in position and drive on such that there is no clearance.

• ‒ Check for axial clearance at 6th speed sliding gear.
• ‒ Permissible axial clearance: 0.15 ... 0.35 mm

• ‒ → Align mark -arrow 3- of paired synchro-hubs -A- and locking collar for 5th and 6th gear -arrow 1-.
• ‒ Simultaneously fit locking collar -arrow 1- with selector fork -arrow 2- on synchro-hub -A- and actuating arm driver for 5th and 6th gear -B- on selector rod -C-.

Notes:

• ◆ Selector fork rib -arrow 2- must face shaft end.
• ◆ Pay attention to holes for spring pin when fitting actuating arm driver on selector rod for 5th and 6th gear.

• ‒ → Press in spring pin -A- such that it is flush.

Notes:

• ◆ Do not drive in spring pin as this could damage selector rod mount.
• ◆ Fit spring pin such that groove is in direction of force transmission as illustrated.

• ‒ Re-determine shim for 5th gear wheel.
• ‒ → Place spacer sleeve -A- (length 39.6 mm) on hollow shaft.
• ‒ On fitting, press circlip home in direction of arrow.
• ‒ Use depth gauge -B- to determine dimension between sleeve and circlip fitted.
• ‒ Determine shim as per table. Part numbers

=> Parts List

Shims available:

• ‒ → Fit selected shim -arrow- on hollow shaft.

• ‒ → Heat 5th gear wheel to approx. 100 °C, fit and drive home such that there is no clearance.
• ‒ Installation position: Collar facing spacer sleeve

• ‒ → Re-determine circlip for 5th gear wheel:
• ‒ Determine thickest circlip which can still just be fitted.
• ‒ Determine circlip from table. Part numbers

=> Parts List

Circlips available:

• ‒ Fit circlip.

• ‒ → Fit inner race for 5th speed sliding gear such that there is no axial clearance.
• ‒ Lubricate needle bearing with gear oil and fit.
• ‒ Place synchro-ring for 5th gear in locking collar.
• ‒ Fit 5th speed sliding gear with spring.

• ‒ → Heat 1st inner race for input shaft ball bearing to approx. 100 °C, fit on input shaft and drive home such that there is no clearance.

• ‒ Check for axial clearance at 5th speed sliding gear.
• ‒ Permissible axial clearance: 0.15 ... 0.35 mm
• ‒ Insert dowel sleeves in bearing plate.
• ‒ Fit new gasket for end cover.

• ‒ → Fit end cover and screw in bolts -arrows B-.

Note:

Do not tighten bolts.

• ‒ Clean and insert 2 magnets -arrows A-.
• ‒ Insert and hand-tighten support plate.
• ‒ Installation position: Lugs facing magnets
• ‒ Diagonally tighten bolts for end cover.

• ‒ → Lubricate 2nd inner race and attach to input shaft with ball contact surface facing input shaft ball bearing and drive on through hole in end cover.
• ‒ Remove support bridge 30-211 A.

• ‒ → Lock input shaft in position by engaging 2 gears (e.g. reverse and 2nd gear); to do so, shift 2 selector plates -arrows-.
• ‒ Tighten multi-point socket-head bolt to 150 Nm.
• ‒ Check neutral position of actuating arm drivers.
• ‒ Selector gates must be aligned

• ‒ → Use screwdriver to unclip cover for oil collector -3- from oil collector -1- at long end and remove magnet -2-.

•     4 -    O-ring
•     5 -    Locating segment

• ‒ Clean oil collector.
• ‒ Assemble oil collector.

• ‒ → Working from inside end cover, guide oil collector support arm first through hole of end cover -arrow- until it is possible to fit O-ring onto oil collector from outside.
• ‒ Lightly lubricate new O-ring and insert.

• ‒ Insert oil pipe of oil collector in input shaft.
• ‒ → Turn oil collector until locating segment comes to rest in milled recess of end cover -arrow-.
• ‒ Press home oil collector.

• ‒ → Slide assembly sleeve -A-, part no. 01E 311 120, onto selector shaft -B-.
• ‒ Install complete selector shaft.
• ‒ Installation position: Chamfer of selector shaft facing downwards

• ‒ → Coat locking bolts -A- for selector shaft with sealing paste AMV 188 001 02 and screw into gearbox housing.
• ‒ Do not interchange aluminium/ steel bolts.
• ‒ Tightening torque:
  Aluminium locking bolt 50 Nm
  Steel locking bolt 70 Nm
• ‒ Lightly lubricate new O-ring for selector shaft cover and insert.
• ‒ Fit cover for selector shaft.
• ‒ Coat bolts -B- (3 x) with sealing paste AMV 188 001 02, insert and tighten to 25 Nm.

• ‒ Slide Torsen differential onto splines of hollow shaft.
• ‒ → Press Torsen differential in direction of arrow and measure distance between top edge of bolted-on end cover and front edge of Torsen differential ball bearing outer race.
• ‒ Determine shim(s) required as per the following table. Part numbers

=> Parts List

Shims available:

• ‒ → Insert dished washer -C- in bearing housing.
• ‒ Installation position: Large diameter (concave side) facing shims
• ‒ Fit shims -B- determined on the basis of table above.
• ‒ Attach spring -A- to end of flange shaft.
• ‒ Lightly lubricate new O-ring for bearing housing and insert.
• ‒ Lubricate small needle bearing in drive pinion.
• ‒ Insert complete bearing housing and pre-tighten evenly.

• ‒ Diagonally finish-tighten bearing housing bolts.

• ‒ Prepare new input shaft oil seal by half filling space between sealing lip and dust lip with sealing grease G 052 128 A1.
• ‒ Lightly lubricate outer periphery of oil seal.
• ‒ Tightly apply thin insulating sheath to splines of input shaft.
• ‒ → Drive in input shaft oil seal.
• ‒ Standard press-in depth: 3.5 mm
• ‒ Service press-in depth: 4.5 mm (if using old input shaft)
• ‒ Remove insulating sheath.
• ‒ Install release bearing, clutch release lever and guide sleeve
  => Page 30-31.
• ‒ Check gearshift operation of gearbox.
• ‒ Attach connecting rod.
• ‒ Top up gear oil in manual gearbox and check oil level => Page 34-143.