Audi Workshop Service and Repair Manuals

Exploded view - servicing gearbox housing

Special tools and workshop equipment required

t	Drift sleeve -VW 244 B-

t	Multi-purpose tool -VW 771-

t	Mandrel -30 - 505-

t	Drift sleeve -40 - 20-

t	-1-Internal puller -Kukko 21/3-

t	Lubricating paste -G 000 150-

t	At present there is no provision for dismantling and assembling the differential.

t	At present there is no provision for removing and installing the pinion shaft.

t	At present there is no provision for adjusting the pinion shaft and crown wheel.

t	Replacement: renew gearbox housing together with installed pinion shaft and differential.

1 -	Intermediate piece

q	Renew if damaged

2 -	Ball-head pin

q

25 Nm

q	Grease bearing surface for clutch release lever with lubricating paste -G 000 150-

3 -

Cap

q	For gearbox breather

4 -	Breather pipe

q	Installation depth → Fig.

q	Clip in cap for gearbox breather

5 -

Oil seal

q	For flange shaft (left-side)

q	Removing and installing → Chapter

6 -	Differential

q	Can currently only be renewed together with gearbox housing and pinion shaft

Differential bevel gears cannot be removed and installed

7 -

O-ring

q	Always renew

q	Lubricate with gear oil

8 -	Cover for final drive

q	Renewing → Chapter

9 -

Bolt

q	20 Nm and then turn 90° further

q	Steel bolts (M8; 38 mm long)

q

10x

10 -	Flange shaft (right-side)

q	With circlip

q	Removing and installing → Chapter

11 -

Oil seal

q	For flange shaft (right-side)

q	Removing and installing → Chapter

12 -	Oil collector

13 -	Pinion shaft

q	Can currently only be renewed together with gearbox housing and differential

14 -	Bearing bush

q	For selector plate / selector fork

q

3x

q	Removing → Fig.

q	Installing → Fig.

15 -	Ball bearing

q	For output shaft

q	Driving out → Fig.

q	Driving in → Fig.

16 -

Circlip

q	Installation position → Fig.

17 -

Circlip

q	Installation position → Fig.

18 -	Ball bearing

q	For input shaft

q	Driving out → Fig.

q	Driving in → Fig.

19 -

Magnet

q

Clean

20 -	Oil drain plug

q

45 Nm

21 -	Gearbox housing

q	Can currently only be renewed together with differential and pinion shaft

Installation dimension of breather pipe Dimension -a- = 21.5 mm

Pulling out bearing bush for selector plate / selector fork A -  Internal puller 18.5 ... 23.5 mm, e.g. -Kukko 21/3-

Driving in bearing bush -arrow- for selector plate / selector fork (drive in onto stop)

Driving output shaft ball bearing out of gearbox housing l  First remove circlip for ball bearing.

Driving output shaft ball bearing -A- into gearbox housing (drive in onto stop) –  Then fit circlip for ball bearing; note correct installation position of circlip → Fig..

Driving input shaft ball bearing -A- out of gearbox housing l  First remove circlip for ball bearing.

Driving input shaft ball bearing -A- into gearbox housing (drive in onto stop) –  Then fit circlip for ball bearing; note correct installation position of circlip → Fig..

Installation position of circlips -A- for ball bearings -B- l  The chamfer -arrow- on circlip -A- faces away from ball bearings -B-.   Note The circlips and ball bearings for the input shaft and output shaft are identical.