Audi Workshop Service and Repair Manuals

Servicing gearbox housing

Special tools and workshop equipment required

t	Press tool -VW 408 A-

t	Tube -VW 423-

t	Press tool -VW 454-

t	Oil seal extractor lever -VW 681-

t	Multi-purpose tool -VW 771-

t	Guide pin -10-15-

t	Drift sleeve -30-100-

t	Mandrel -30-505-

t	Installing tool -40-503-

t	Punch -2062-

t	-1-Internal puller -Kukko 21/5-

t	Torque wrench -V.A.G 1331-

Gearbox housing - exploded view of components

t	Observe the general repair instructions → Chapter.

t	Adjustment is required if cover for final drive, gearbox housing or tapered roller bearings are being renewed → Anchor.

1 -

Oil seal

q	For flange shaft

q	Pulling out → Fig.

q	Driving in → Fig.

q	Fill space between sealing lips with sealing grease

q	Renewing with gearbox installed → Chapter

2 -	Cover for final drive

3 -

O-ring

q	For cover for final drive

q

Renew

4 -

Shim “S1”

q	Note thickness

q	Table of adjustments →

5 -	Large tapered roller bearing outer race

q	For differential

q	Driving out and driving in → Fig.

6 -	Small tapered roller bearing outer race

q	For differential

q	Driving out and driving in → Fig.

7 -

Shim “S2”

q	Note thickness

q	Table of adjustments →

8 -

Oil seal

q	For input shaft

q	Levering out → Fig.

q	Driving in → Fig.

q	Renewing after removing input shaft

q	Renewing when gearbox is not dismantled → Fig. and → Fig.

9 -	Oil drain plug, 40 Nm

10 -	Ball sleeve

q	For selector shaft

q	Renew after removing

q	Pulling out → Fig.

q	Driving in → Fig.

11 -	Ball sleeves

q	For selector shafts

q	Renew after removing

q	Pulling out → Fig.

q	Driving in → Fig.

12 -

Circlip

q	Installation position: eyes facing up

13 -	Reversing light switch -F4-

q	Removing and installing → Fig.

14 -

O-ring

q	For cover for selector shaft

q

Renew

15 -	Cover for selector shaft

q	Removing → Anchor

q	Installing → Anchor

16 -	Ball head stud, 20 Nm

q	For connecting rod

17 -	Large tapered roller bearing outer race

q	For pinion shaft

q	Pulling out → Fig.

q	Pressing in → Fig. and → Fig.

18 -

Circlip

q	Removing → Fig.

19 -

Shim “S3”

q	Note thickness

q	Table of adjustments → Anchor

20 -	Needle bearing for input shaft

q	Pulling out → Fig.

q	Driving in → Fig.

q	Measuring insertion depth → Fig.

21 -	Locking bolts for selector shaft

q	Removing → Anchor

q	Fit bolts with sealing paste -AMV 188 001 02- → Anchor

q	Tighten to 50 Nm

22 -	Trunnion bolt, 40 Nm

q	For push rod

23 -

Breather

q	Clip cap on

q	Insertion depth of sleeve → Fig.

24 -	Oil seal for selector shaft

q	Can be renewed when gearbox is removed but not dismantled

q

Renew

q	Pulling out → Fig.

q	Driving in → Fig.

q	Always use assembly sleeve for installing → Fig.

25 -	Gearbox housing

26 -

Magnet

q

Clean

q	When renewing gearbox housing drive in with e.g. press tool -VW 408 A-

27 -	Speedometer sender -G22-

q	Not fitted from 07.2002

q	Removing and installing → Chapter

28 -

O-ring

q

Renew

29 -	Oil filler plug, 40 Nm

Pulling out oil seal for flange shaft   Note t  Illustration shows removal of oil seal on right-hand side of gearbox. t  The procedure is the same on both sides.

Driving in oil seal for flange shaft –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. l  Insertion depth: 5.5 mm. l  Insertion depth for repairs is 6.5 mm when a used flange shaft is employed.   Note t  Illustration shows installation of oil seal on right-hand side of gearbox. t  The procedure is the same on both sides.

Levering out oil seal for input shaft when gearbox is dismantled –  Pry out oil seal carefully using oil seal extractor lever -VW 681-.

Removing oil seal for input shaft when gearbox is not dismantled –  Use screwdriver to carefully pry out the oil seal -arrow-.   Note Take care not to damage contact surface for oil seal on input shaft.

Driving in oil seal for input shaft –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Fit a thin insulating hose tightly over splines of input shaft. –  Drive in input shaft oil seal. l  Insertion depth: 3.5 mm. l  Driving-in depth when re-installing a used input shaft (repairs): 4.5 mm. –  Remove insulating hose.

Pulling out ball sleeve –  Remove circlip. A -  Internal puller 14.5 ... 18.5 mm -Kukko 21/2-

Driving in ball sleeve –  Install ball sleeve with the inscribed side (thicker metal) facing the drift. –  Drive in ball sleeve as far as stop. –  Fit circlip.

Pulling out seal for selector shaft   Note With gearbox removed but not dismantled, pry out seal carefully using a screwdriver without damaging shaft.

Driving in seal for selector shaft l  Selector shaft installed or removed. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Fit assembly sleeve onto selector shaft → Fig.. –  Drive seal onto stop in housing.

Installing seal and selector shaft with assembly sleeve –  Use assembly sleeve -01E 311 120--item A- to avoid damaging the seal -C- when installing.

Insertion depth of breather sleeve A - previous version: Insertion depth -a-= 21 mm. B - new version: Insertion depth -b-= 20 mm.

Removing and installing reversing light switch -F4- –  Tighten reversing light switch -F4--item A- to 20 Nm when installing.

Pulling needle bearing out of gearbox housing A -  Internal puller 30 ... 37 mm -Kukko 21/5-

Driving needle bearing into gearbox housing l  Installation position: inscription on bearing faces tool. l  Insertion depth → Fig.

Insertion depth of needle bearing l  Dimension -a- = 105 mm

Removing circlip –  Lift circlip out of the groove by turning one end of the circlip -arrow- with a screwdriver -A-. –  Secure this end with a second screwdriver -B-. –  Lever circlip out further by repositioning screwdriver -A-.