Audi Workshop Service and Repair Manuals

Exploded view - servicing gearbox housing

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Press tool -VW 408 A-

t	Tube -VW 423-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Guide pin -10 - 15-

t	Installing tool -40 - 503-

t	Torque wrench -V.A.G 1331-

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

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

t  Drift -T40085- t  Assembly sleeve -01E 311 120-

1 -	Gearbox housing

q	When renewing: adjust input shaft → Chapter, adjust pinion shaft/hollow shaft and differential (final drive gear set) → Chapter

2 -	Oil seal for selector shaft

q	Pulling out → Fig.

q	Driving in → Fig.

q	→ Chapter „Renewing oil seal for selector shaft with gearbox installed“

q	→ Chapter „Renewing oil seal for selector shaft with gearbox removed (gearbox remains assembled)“

q	Always use assembly sleeve -01E 311 120- to fit oil seal (if selector shaft remains installed in gearbox) → Fig.

3 -	Tapered roller bearing outer race (right-side)

q	For differential

q	If renewing: adjust differential (crown wheel) → Chapter

q	Removing and installing → Item

4 -

Shim „S2“

q	Note thickness

q	Table of adjustments → Chapter

5 -

Bush

q	Secures magnet → Item

q	Drive in (for example, with press tool -VW 408 A- when renewing gearbox

6 -

Magnet

q

Clean

7 -	Ball-head pin

q

25 Nm

q	Lubricate with grease for clutch plate splines -G 000 100-

8 -	Oil drain plug

q

45 Nm

9 -

Oil seal

q	For flange shaft (right-side)

q	Removing and installing → Chapter

10 -	Locking bush

q	For selector rod for 1st and 2nd gear

q	Removing and installing → Fig.

11 -	Locking bush

q	For reverse gear selector rod

q	Removing and installing → Fig.

12 -	Ball sleeve

q	For selector rod for 1st and 2nd gear

q	Pulling out → Fig.

q	Drive in until flush using guide pin -10 - 15-

13 -	Ball sleeve

q	For selector rod for 3rd and 4th gear

q	Pulling out → Fig.

q	Drive in until flush using guide pin -10 - 15-

14 -

Shim „S3“

q	Note thickness

q	Table of adjustments → Chapter

15 -	Outer race of double tapered roller bearing

q	For pinion shaft

q	Removing and installing → Item

16 -

Bolt

q

24 Nm

q	Secures needle bearing → Item for input shaft

17 -	Needle bearing

q	For input shaft

q	Driving out → Fig.

q	Driving in → Fig.

18 -	Oil collector

q	With magnet

q	Installation position in gearbox housing → Fig.

19 -	Ball sleeve

q	For selector shaft

q	Pulling out → Fig.

q	Driving in → Fig.

20 -

Cap

q	For gearbox breather

21 -	Breather pipe

q	Drive in onto stop

q	Clip in cap for gearbox breather

Pulling out oil seal for selector shaft with gearbox dismantled

Installing oil seal -C- with selector shaft installed –  Push assembly sleeve -01E 311 120--A- onto selector shaft -B-.

Driving in oil seal for selector shaft –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of oil seal. –  Drive oil seal -arrow- into housing as far as it will go.

Removing and installing locking bush for selector rod –  Drive out the used locking bush -A- inwards into gearbox housing. –  Drive in new locking bush into gearbox housing -B- until flush.

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

Driving out input shaft needle bearing from gearbox housing –  Unscrew bolt for securing needle bearing → Fig.. –  Fit adapter -VW 295 A- with smaller outside diameter into needle bearing. –  Drive out needle bearing with drift -VW 295-.

Pressing in input shaft needle bearing until limit stop –  Secure needle bearing after pressing in → Fig..

Securing input shaft needle bearing –  Secure input shaft needle bearing with bolt -2-. –  Then insert oil collector -1- into gearbox housing.

Pulling out selector shaft ball sleeve A -  Internal puller 14.5 ... 18.5 mm, e.g. -Kukko 21/2-

Driving in ball sleeve for selector shaft Fit ball sleeve so that side with lettering (thicker metal) faces guide pin -10 - 15-. –  Drive in ball sleeve until flush.