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	Locking fluid -AMV 185 101 A1-

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	On replacement: Replace the gearbox housing with the pinion shaft and differential fitted.

1 -	Intermediate piece

q	Renew if damaged

2 -	Ball-head pin

q

25 Nm

q	Coat the bearing surface for the clutch release lever with grease for clutch plate splines -G 000 100-

3 -

Oil seal

q	For flange shaft (left-side)

q	Removing and installing → Chapter

4 -	Differential

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

Differential bevel gears cannot be removed and installed

5 -

O-ring

q	Always renew

q	Lubricate with gear oil

6 -	Cover for final drive

q	Renewing → Chapter

7 -

Bolt

q

24 Nm

q	Steel bolts (M8; 42 mm long)

q

10x

8 -	Flange shaft (right-side)

q	With circlip

q	Removing and installing → Chapter

9 -

Oil seal

q	For flange shaft (right-side)

q	Removing and installing → Chapter

10 -	Bearing bush

q	For selector plate / selector fork

q

2x

q	Removing → Fig.

q	Installing → Fig.

11 -	Pinion shaft

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

12 -

Plate

q	For securing ball bearings in gearbox housing

q	Installation position: Countersinks for bolts facing gearbox cover

13 -

Bolt

q

24 Nm

q	Apply locking fluid -AMV 185 101 A1- when fitting

14 -	Ball bearing

q	For output shaft

q	Bearing height = 19 mm

q	Not to be interchanged with ball bearing → Item

q	Driving out → Fig.

q	Driving in → Fig.

15 -	Ball bearing

q	For input shaft

q	Bearing height = 17 mm

q	Not to be interchanged with ball bearing → Item

q	Driving out → Fig.

q	Driving in → Fig.

16 -	Oil drain plug

q

40 Nm

17 -	Gearbox housing

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

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)

Removing and installing plate -A- for securing ball bearings –  Screw out the bolts -arrows- to remove the plate -A-.   Note Prior to fitting, remove any residual locking fluid from the threads of the bolts -arrows- using a wire brush, for example. Then apply locking fluid -AMV 185 101 A1- and insert the bolts. –  Working outwards, tighten the bolts -arrows- diagonally to torque → Item.

Driving output shaft ball bearing out of gearbox housing l  First remove the plate for securing the ball bearings → Fig..

Driving output shaft ball bearing -A- into gearbox housing (drive in onto stop)   Note Take care not to interchange the ball bearings for the input and output shaft, as their heights differ. –  Then fit the plate for securing the ball bearings → Fig..

Driving input shaft ball bearing -A- out of gearbox housing l  First remove the plate for securing the ball bearings → Fig..

Driving input shaft ball bearing -A- into gearbox housing (drive in onto stop)   Note Take care not to interchange the ball bearings for the input and output shaft, as their heights differ. –  Then fit the plate for securing the ball bearings → Fig..