Audi Workshop Service and Repair Manuals

Exploded view - 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	Support plate -VW 801-

t	Guide pin -10 - 15-

t	Thrust ring -2006 A-

t	Tube -2010-

t	Tube -2040-

t	Centring mandrel -3176-

t  -1-Internal puller -Kukko 21/2- t  -1-Internal puller -Kukko 21/5- 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 -	Needle bearing

q	Bearing for hollow shaft in gearbox cover

q	Pressing 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

q

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.

10 -

O-ring

q	Always renew

Pressing needle bearing out of gearbox cover

Pressing needle bearing into gearbox cover Support gearbox cover with tube -2010- 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 out roller bearing from 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.

Carefully press in new roller bearing into gearbox cover until limit stop. Support gearbox cover below bearing seat using thrust ring -2006 A-.

Securing 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 hexagon socket head bolt -3- to 24 Nm.

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-.