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	Thrust pad -VW 512-

t	Tube -VW 519-

t	Thrust plate -VW 447 i-

t	Support plate -VW 801-

t	Guide pin -10 - 15-

t	Centring mandrel -3176-

t	Torque wrench -V.A.G 1331-

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

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

t	-1-Internal puller -Kukko 21/6-

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

1 -	Gearbox cover

q	Fit sealing plug on new gearbox cover → Item

q	Drive in new sealing plug until flush → Fig.

2 -	Dowel sleeve

q

2x

q	For centralising gearbox cover on bearing housing

q	Drive out and in with drift -3121-

3 -	Roller bearing

q	Bearing for output shaft in gearbox cover

q	Always renew

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Roller bearing

q	Bearing for input shaft in gearbox cover

q	With oil guide

q	Always renew

q	Pulling out → Fig.

q	Pressing in → Fig.

5 -	Ball sleeve

q	For selector rod for 1st and 2nd gear

q	Pulling out → Fig.

q	Driving in → Fig.

6 -	Ball sleeve

q	For selector rod for 5th and 6th gear

q	Pulling out → Fig.

q	Driving in → Fig.

7 -	Multi-point socket head bolt, 24 Nm

8 -	Retaining plate

q	Secures needle bearing → Item and needle roller bearing → Item in gearbox cover

q	Installation position → Fig.

9 -	Sealing plug

q	Drive in flush → Fig.

Pulling roller bearing for output shaft out of gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6-   Note Always renew roller bearing after pulling out.

Pressing new roller bearing for output shaft into gearbox cover as far as the stop (press in carefully) Support gearbox cover with thrust plate -VW 447 i- directly below bearing mounting.

Pulling out ball sleeve -C- from gearbox cover A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2-

Driving ball sleeve into gearbox cover until flush Fit ball sleeve -1- and -2- so that side with lettering (thicker metal) faces guide pin -10 - 15- or centring mandrel -3176-.   Note Due to the housing depth use centring mandrel -3176- for driving in ball sleeve -2-.

Pulling roller bearing for input shaft out of gearbox cover Shorten (cut off) oil guide in roller bearing in order to insert internal puller-B-. A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 30 ... 37 mm, e.g. -Kukko 21/5-   Note Always renew roller bearing after pulling out.

Pressing new roller bearing for input shaft into gearbox cover as far as the stop (press in carefully) Support gearbox cover with thrust plate -VW 447 i- directly below bearing mounting.

Securing needle roller bearing and needle bearing in gearbox cover. –  Insert retaining plate -2- with the high shoulder -arrow- facing needle bearing -1- into gearbox cover. –  Tighten bolt -3- to specified torque → Item.

Drive in plug until flush -arrow-   Caution Depending on the version, a new gearbox cover can be supplied with or without the sealing plug -arrow-.