Audi Workshop Service and Repair Manuals

Gearbox installed

Special tools, testers and auxiliary equipment required

• ◆ Thrust plate VW 401
• ◆ Press tool VW 412
• ◆ Thrust plate VW 402
• ◆ Thrust pad VW 454
• ◆ Press tool VW 407
• ◆ Sleeve 30-21

• ◆ Sleeve 40-20
• ◆ Thrust pad 3118
• ◆ Item 3 Separating tool Kukko 17/2

Notes:

• ◆ Rules for cleanliness when working on the automatic gearbox .
• ◆ General repair instructions => Page 00-34.

The parts shown in the following illustration can be removed with the gearbox installed.

• Hexagon socket-head bolt
  - 25 Nm
• Flange shaft, rear
• Sealing ring
• ◆ Replacing => Page 39-61.
• Release and tighten bolt - 23 Nm
• ◆ 4 pieces
• Housing cover
• O-ring
• ◆ Lubricate with gear oil
• Circlip
• Grooved ball bearing
• ◆ For spur gear 1
• ◆ Pressing off
  => Fig.39-55
• ◆ Pressing on
  => Fig.39-55

• for spur gear 1
• ◆ For rear final drive set
• ◆ If damaged, always renew together with spur gear 2 -17- Replace
• ◆ To remove and install pull out towards rear together with -7- and -8- from transfer gear housing
• Circlip
• Needle bearing
• ◆ For spur gear 1
• ◆ Only remove bearing in order to renew
• ◆ To replace, heat transfer gear housing to approx. 100 °C and drive out needle bearing to rear with drift (Warning: Wear protective gloves)
• ◆ Drive in up to stop using sleeve 30-21

• Release and tighten bolt - 23 Nm
• ◆ Loosen and tighten in diagonal sequence
• Transfer gear housing
• Tensioning nut
• ◆ For rear flange shaft
  -2-
• Needle bearing
• ◆ For spur gear 2
• ◆ Only remove bearing in order to renew
• ◆ Replacing => Page 39-69.
• Circlip
• for spur gear 2
• ◆ For rear final drive set
• ◆ When damaged, always renew together with spur gear 1 -9-
• ◆ To remove and install, dismantle transfer gear housing => Page 39-57 and pull out together with - 18, 19, 23-

• Grooved ball bearing
• ◆ For spur gear 2
• ◆ Pressing off
  => Fig.39-56
• ◆ Pressing on
  => Fig.39-56
• Circlip
• ◆ For securing grooved ball bearing -18- in transfer gear housing
• Washer
• ◆ For groove ball bearing -Item 18-
• ◆ Before installing, clip on alignment plate -21-
• Alignment plate
• Release and tighten bolt -10 Nm
• Circlip
• ◆ To secure grooved ball bearing -18- on spur gear 2 -17-

• Gasket
• ◆ Replacing => Page 39-57.
• Torsen differential
• ◆ Renew complete if damaged
• ◆ Removing and installing
• Sealing ring
• ◆ Replacing => Page 39-65.
• Solenoid
• ◆ Removing and installing
• Dowel sleeve
• ◆ 2 pieces
• Breather
• ◆ For transfer gear
• ◆ Cap is fitted on breather
• ◆ Installation position: Breather must protrude 10 ... 11 mm from housing without cover

• Release and tighten bolt - 23 Nm
• ◆ Observe the tightening sequence
• Intermediate drive for front axle drive
• Gasket
• ◆ Replacing => Page 39-24.
• Dowel sleeve
• Input pinion
• ◆ For front final drive
• ◆ Removing and installing
• Intermediate pinion
• ◆ For front final drive
• ◆ Installation position: gear identification faces towards transfer gear

• Output pinion
• ◆ For front final drive
• ◆ Installation position: gear identification faces towards transfer gear
• Sealing ring
• ◆ Replacing => Page 39-67.

→ Fig1    Pressing off grooved ball bearing for spur gear 1

•     A -    Separating device 22 ... 4.53 in, e.g. Kukko 17/2

→ Fig2    Pressing on grooved ball bearing for spur gear 1

→ Fig3    Pressing off grooved ball bearing for spur gear 2

•     A -    Separating device 22 ... 4.53 in, e.g. Kukko 17/2

→ Fig4    Pressing on grooved ball bearing for spur gear 2