Audi Workshop Service and Repair Manuals

Removing and installing bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, pinion shaft and hollow shaft

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Thrust plate -VW 447 H-

t	Press tool - VW 454-

t	Engine and gearbox support -VW 540-

t	Oil seal extractor lever -VW 681-

t	Multi-purpose tool -VW 771-

t	Extension -30-23-

t	Drift sleeve -30-100-

t	Support bridge -30-211 A-

t	Press tool -40-21-

t	Locking pin -2064-

t	Clamping sleeve -3116-

t	Press tool -3118-

t	Drift -3121-

t	Internal puller -3275-

t  Press tool -3276-

t  Used oil collection and extraction unit -V.A.G 1782-

t  -1-Two-arm puller -Kukko 20/10- t  -2-Hooks -Matra V/170- t  Depth gauge

Removing –  Secure gearbox to engine/gearbox support -VW 540-. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Drain gear oil (2 oil drain plugs).

–  Slacken off bolt -1- and remove leaf spring -2-. –  Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-. –  Unbolt guide sleeve.

–  Unbolt bearing housing -arrow- and pull off.   Note

When pulling off, the bearing housing is pressed slightly off the end cover by the spring -A-. –  When removing the bearing housing, note position of dished spring -C-. l  Outer diameter (concave side) faces shims -B-. –  Remove shims -B-, note thickness and re-determine if necessary → Anchor.

–  Pull Torsen differential out of end cover.

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

–  Swing oil collector -arrow- down and guide out through hole in end cover. –  Remove oil collector.

–  Remove locking bolts -A- for selector shaft from gearbox housing. –  Remove 3 bolts -B- for selector shaft cover and remove cover. –  Pull out selector shaft.

–  Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear); do this by moving two gear selector plates -arrows-.

–  Unscrew multi-point socket head bolt -arrow B- in input shaft through hole -arrow A- in end cover. –  Remove the two securing bolts -arrows C- for end cover at needle bearing support plate -arrow D-. –  Remove support plate.

–  Remove and clean the 2 magnets -arrows A-. –  Unscrew the 5 bolts -arrows B- securing end cover.

–  Pull off 2nd inner race for input shaft ball bearing from input shaft. A -  Washer   Note The internal puller -3275- engages in a circular groove in the inner race when pulling off -arrow-. –  Remove end cover with end cover/intermediate housing gasket. –  Pull dowel sleeves out of intermediate housing.

–  Pull off 5th speed selector gear and spring together with 1st inner race -A- for input shaft ball bearing. B -  Two-arm puller -Kukko 20/10- –  Take out synchro-ring for 5th gear. –  Take out circlip for 5th gear wheel. –  Lock hollow shaft in position by engaging two gears → Anchor.

–  Pull off 5th gear wheel.   Note Always use hexagon bolt (length 50 mm) for clamping sleeve -3116-. C -  Two-arm puller -Kukko 20/10- with hook, 200 mm –  Remove shim -B- for 5th speed gear, note thickness and re-determine if necessary → Anchor. –  Remove spacer sleeve -A-.

–  Press out roll pin -A- for selector fork for 5th and 6th gear.   Note t  Do not damage synchro-ring for 6th gear when pressing out roll pin. t  Do not drive out roll pin, otherwise selector rod bearing will be damaged. –  Take hold of follower and pull selector rod together with selector fork for 5th and 6th gear and locking collar as far as possible away from intermediate housing (until stop is felt).

–  Mark locking collar for 5th and 6th gear -arrow 1- and synchronising hub -A- (paired) in installation position -arrow 3-.

–  Detach follower together with selector fork and locking collar from selector rod.

–  Pull off 6th speed selector gear, synchro-ring for 6th gear, synchronising hub for 5th and 6th gears and needle bearing inner race for 5th speed selector gear. A -  Two-arm puller -Kukko 20/10- with hook, 200 mm

–  Remove selector rod locking bolts. A -  1st and 2nd gear B -  3rd and 4th gear C -  5th and 6th gear D -  Reverse gear –  Drive out dowel sleeves from intermediate housing and unbolt intermediate housing from gearbox housing. –  Secure pinion shaft relative to hollow shaft e.g. with hose clip, to prevent it falling out. –  Separate intermediate housing with input shaft, pinion shaft, hollow shaft and internal selector mechanism (as a single unit) from gearbox housing.

–  Remove circlip from selector rod for 1st and 2nd gear and take off follower -A-. –  Pull out selector rod -B- for 5th and 6th gear. –  Remove follower -C- for reverse gear.

–  Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft. –  Use right-angled circlip pliers to remove circlip -arrow B- for inner race for roller bearing. –  Remove inner race for roller bearing -arrow C- (not a press fit).

–  Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from intermediate housing.

–  Unscrew hexagon bolt -D- and take off spring clip -B- and retaining plate -A-. Then pull out shaft -C- for reverse gear wheel. –  Take out spring, synchro-ring and reverse gear wheel. –  Remove relay lever for reverse gear.   Note t  Pinion shaft and hollow shaft can be removed complete if the 6th speed gear can be easily levered off. t  If it is necessary to press off the 6th speed gear, the pinion shaft must be pulled out of the hollow shaft. –  Remove the securing element fitted previously in order to prevent the pinion shaft from falling out.

–  Pull pinion shaft out of hollow shaft -arrow D-, when doing this catch the tapered rollers -arrow A- (Qty. 23). –  Remove corrugated spring -arrow B- and needle roller bearing -arrow C-.   Note Carefully protect bearings from dirt, clean if necessary.

–  Check bearings for completeness: 1 -  Flange ring - tapered contact surface to tapered rollers 2 -  Tapered rollers (Qty. 23) - with larger diameter facing towards pinion shaft head 3 -  Support ring - tapered contact surface to tapered rollers 4 -  Corrugated spring 5 -  Circlip for tapered roller bearing for pinion shaft

–  Press off 6th gear wheel.   Note Because of the type of fit, it may be possible to press gear off easily. –  Remove hollow shaft (or pinion shaft and hollow shaft) from intermediate housing together with selector rod and selector fork for 1st and 2nd gear.

Installing –  Insert hollow shaft into intermediate housing together with selector fork and selector rod for 1st and 2nd gears (without follower).   WARNING Wear protective gloves. –  Heat 6th gear wheel to approx. 100 °C, fit and press onto stop so it is free of play. l  Installation position: shoulder towards tapered roller bearing.

–  Insert tapered roller bearing for pinion shaft/hollow shaft with grease -G 052 128 A1-. Arrangement: 1 -  Flange ring - tapered contact surface to tapered rollers 2 -  Tapered rollers (Qty. 23) - with larger diameter facing towards pinion shaft head 3 -  Support ring - tapered contact surface to tapered rollers 4 -  Corrugated spring 5 -  Circlip for tapered roller bearing for pinion shaft

–  Oil needle bearing -C- thoroughly. A -  Flange ring, tapered rollers (Qty. 23), and support ring B -  Corrugated spring C -  Needle roller bearing D -  Hollow shaft –  Insert pinion shaft into hollow shaft and secure with hose tie to prevent slipping out.

–  Fit relay lever -A- for reverse gear onto bolt for relay lever (note pin; limits travel of relay lever towards synchro-ring). –  Insert selector gear -B- and engage relay lever with groove on selector gear. –  Insert synchro-ring -C-. l  Installation position: position flat on circumference of synchro-ring towards input shaft (not as yet fitted) -arrow 1-. –  Insert spring. l  Installation position: hook single angled end into recess on synchro-ring -arrow 2-. Turn double angled end anti-clockwise and insert into opening on intermediate housing -arrow 3-.

–  Insert shaft for reverse gear wheel -C-. –  Position retaining plate -A-. l  Installation position: chamfers of holes for locking pins of the synchro-ring face intermediate housing. –  Insert spring clip -B- into synchro-ring locking pins. –  Renew self-locking bolt -D- and tighten to 25 Nm.

–  Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into the intermediate housing. l  Installation position of selector fork: rib towards follower → Item.

–  Fit roller bearing inner race -arrow C- on input shaft. –  Use right-angled circlip pliers to fit circlip -arrow B-.

–  Engage recess in follower for reverse gear with the free end of relay lever -arrow A-. –  Slide selector rod for 5th and 6th gear through follower for reverse gear in direction of -arrow B-.

–  Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips. –  Lubricate selector rods and all bearings of input shaft and pinion shaft/hollow shaft in gearbox housing and intermediate housing with gear oil.

–  Carefully pry used input shaft oil seal out of gearbox housing using extractor lever -VW 681-. –  Coat sealing surfaces between intermediate housing and gearbox housing with sealing paste -AMV 188 001 02-. –  Insert intermediate housing with gear cluster in gearbox housing.   Note When inserting the intermediate housing with gear cluster, ensure that the selector rods align with their bearings. –  Drive in the 2 dowel sleeves locating intermediate housing on gearbox housing. –  Tighten the 12 bolts in diagonal sequence to 25 Nm.

–  Apply sealing paste -AMV 188 001 02- to locking bolts for selector rods and tighten bolts to 50 Nm. A -  1st and 2nd gear B -  3rd and 4th gear C -  5th and 6th gear D -  Reverse gear

–  Push thrust washer -arrow A- for needle bearing for 6th gear onto shaft. l  Installation position: shoulder towards circlip -arrow B-, smooth contact surface towards end of shaft. –  Oil needle bearing for 6th speed selector gear with gear oil and fit. –  Slide on 6th speed selector gear with spring and synchro-ring. l  Synchro-ring installation position: the lugs of the synchro-ring engage into the recesses below in the selector gear.

–  Support the input shaft with the support bridge -30-211 A-.

–  Note correct position of synchronising hub for 5th and 6th gears. l  Side with projecting face -arrow 1- faces end of shaft. l  The oil drilling in the input shaft -arrow 2- and the oil groove in the synchronising hub -arrow 3- are in line   WARNING Wear protective gloves.

–  Heat synchronising hub for 5th and 6th gear to approx. 100 °C, fit and drive on; ensure there is no play. –  Check 6th speed selector gear for axial play. l  Permissible axial clearance: 0.15 ... 0.35 mm.

–  Align markings -arrow 3- on paired synchronising hub -A- and locking collar for 5th and 6th gears -arrow 1-. –  Fit locking collar -arrow 1- with selector fork -arrow 2- onto synchronising hub -A- as well as follower for 5th and 6th gear -B- onto selector rod -C- at the same time. l  Rib on selector fork -arrow 2- must face towards end of shaft.   Note When sliding follower onto selector rod for 5th and 6th gear pay attention to holes for roll pin.

–  Press in roll pin -A- until flush.   Note t  Do not drive in roll pin, otherwise selector rod bearing will be damaged. t  When fitting the roll pin, the slot must be in line with the direction of force, as shown in the illustration.

–  Re-determine shim for 5th gear wheel. –  Fit spacer sleeve -A- (length 39.6 mm) onto hollow shaft. –  When fitting, push circlip in the direction of -arrow- onto stop. –  Determine distance between sleeve and fitted circlip using a depth gauge -B-. –  Select required shim thickness from following table:

Measuring range (mm)	Available shims - Thickness of shims in mm 1)
31.01 … 31.11	1.05
31.11 … 31.21	1.15
31.21 … 31.31	1.25
31.31 … 31.41	1.35
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit selected shim -arrow- onto hollow shaft.   WARNING Wear protective gloves.

–  Heat 5th gear wheel to approx. 100 °C, fit and drive onto stop free of play. l  Installation position: shoulder towards spacer sleeve.

–  Re-determine circlip for 5th gear wheel. –  Determine the thickest circlip that can still just be fitted. –  Select required circlip thickness from following table:

Available circlips - Thickness in mm 1)
2.32	2.40	2.48
2.34	2.42	2.50
2.36	2.44
2.38	2.46
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit circlip.

–  Drive on inner race for needle bearing for 5th speed selector gear so there is no axial clearance. –  Lubricate needle bearing with gear oil and fit bearing. –  Insert synchro-ring for 5th gear in locking collar. –  Slide on 5th speed selector gear with spring.   WARNING Wear protective gloves.

–  Heat 1st inner race of ball bearing for input shaft to approx. 100 °C, fit on input shaft and drive onto stop so it is free of play. –  Check 5th speed selector gear for axial play. l  Permissible axial clearance: 0.15 ... 0.35 mm. –  Insert dowel sleeves in intermediate housing.

–  Place new gasket for end cover in position. –  Position end cover and fit bolts -arrows B-.   Note Do not tighten bolts at this stage. –  Clean the two magnets -arrows A- and fit magnets. –  Insert support plate and tighten bolts by hand. l  Installation position: Lugs towards magnets. –  Then tighten end cover bolts in diagonal sequence.

–  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 by engaging 2 gears (e.g. reverse and 2nd gear); do this by moving two gear selector plates -arrows-. –  Tighten multi-point socket head bolt to 150 Nm. –  Check that followers are in neutral. l  Selector gates must align.

–  Unclip cover -3- from oil collector -1- by applying screwdriver at long nose of cover and remove magnet -2-. 4 -  O-ring 5 -  Positioning segment –  Clean oil collector. –  Assemble the oil collector.

–  Guide oil collector from interior of end cover with support arm leading through the hole of the end cover -arrow-, until the O-ring can be fitted from outside onto the oil collector. –  Lightly oil new O-ring and fit.

–  Insert oil pipe of oil collector in input shaft. –  Turn oil collector until the positioning segment is located in the machined recess of the end cover -arrow-. –  Press in oil collector onto stop.   Note

Use assembly sleeve -01E 311 120--item A- to avoid damaging the seal -C- when installing. –  Install complete selector shaft. l  Installation position: Chamfer of selector shaft points downwards.

–  Apply sealing paste -AMV 188 001 02- to locking bolts -A- for selector shaft, fit bolts in gearbox housing and tighten to 50 Nm. –  Lightly oil new O-ring for cover for selector shaft and fit. –  Fit cover for selector shaft. –  Apply sealing paste -AMV 188 001 02- to 3 bolts -B-, fit bolts 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 the bolted end cover and front edge of outer race of ball bearing for Torsen differential. –  Select thickness of required shim(s) from following table:

Measuring range (mm)	Shims - Thickness of shims in mm 1)
7.05 … 7.30	1.65 + 1.45 +1.20
7.30 … 7.55	1.65 + 1.45 + 0.95
7.55 … 7.80	1.65 + 1.45 + 0.70
7.80 … 8.05	1.65 + 1.45 +0.45
8.05 … 8.25	1.65 + 1.65
8.25 … 8.50	1.65 + 1.45
8.50 … 8.75	1.65 +1.20
8.75 … 9.00	1.65 + 0.95
9.00 … 9.25	1.65 + 0.70
9.25 … 9.50	1.65 + 0.45
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit dished spring -C- into bearing housing. l  Installation position: larger diameter (concave side) towards the shims. –  Fit shims -B- as selected from table. –  Fit spring -A- onto end of flange shaft. –  Lightly oil new O-ring for bearing housing and fit O-ring. –  Oil small needle bearing in pinion shaft. –  Insert complete bearing housing and pull home evenly. –  Tighten bearing housing bolts in diagonal sequence. –  Fill space between sealing lip and dust lip of new oil seal for input shaft with a thin coat of grease -G 052 128 A1-. –  Fit a thin insulating hose tightly over splines of input shaft.

–  Drive in input shaft oil seal. l  Installation depth when fitted at factory: 3.5 mm. l  Driving-in depth when re-installing a used input shaft (repairs): 4.5 mm. –  Remove insulating hose. –  Install release bearing, clutch release lever and guide sleeve → Chapter. –  Select all gears. –  Position connecting rod. –  Fill manual gearbox with gear oil and check oil level → Chapter.