Audi Workshop Service and Repair Manuals

Removing and installing input shaft Special tools and workshop equipment required

t  Workshop hoist -VAS 6100-

t  Puller -T40050-

t  Thrust piece -T40099- Removing   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. l  Gearbox must be removed and secured in a vertical position on engine and gearbox support → Chapter. l  Thrust piece -T40099- must be modified for use with multitronic gearbox 0AW, front-wheel drive → Chapter. –  Drain ATF → Chapter. To do so, swivel gearbox into installation position (horizontal).   Note Gearbox must not be turned such that flange points downwards.

–  Mark installation position of input shaft cover with paint -arrows-.

–  Remove circlip -1-.

–  Apply puller -T40050- to input shaft. –  Check that puller is securely attached to input shaft. l  The circlip must be pushed all the way down. –  Use workshop hoist -VAS 6100- and puller -T40050- to pull input shaft together with cover and forward clutch out of gearbox housing -arrow-.   Note The input shaft cover is difficult to remove from the gearbox housing. Apply tension to input shaft with workshop hoist -VAS 6100- and carefully apply hammer blows to flange of gearbox bellhousing using plastic hammer and a suitable piece of wood until cover comes loose.

Caution A damaged oil pipe will cause problems when driving off from a standstill or complete gearbox failure. The input shaft must not be laid down on the projecting oil pipe -arrow-.

–  Place input shaft on thrust piece -T40099-.

Installing Installation is carried out in reverse sequence; note the following: –  Assess wear on gearbox components → Chapter. –  Remove bolts -arrows- and pull ATF filter out of gearbox housing. –  Clean sealing surfaces on gearbox housing and input shaft cover. –  Adjust and install reverse gear clutch → Chapter.

–  Check that dowel sleeves -arrows- (for locating input shaft cover) are securely fitted.

–  Renew axial sealing element -arrow-. l  Installation position: sealing lip faces upwards towards input shaft cover. –  Renew O-ring for input shaft cover and lubricate lightly with ATF.

–  Align plates of reverse gear clutch using a straight-edge or similar. l  The teeth must be set exactly in line.

–  Check installation dimension of oil pipe -arrow-: l  With oil pipe fully inserted, distance -a- from end of oil pipe to input shaft should be approx. 11.5 mm.   Note t  If the distance is less, the oil pipe may be damaged (the end could have broken off if the oil pipe was pushed in too far). t  If the distance is larger, the oil pipe is not pushed in far enough.   Caution A damaged oil pipe will cause problems when driving off from a standstill or complete gearbox failure. The input shaft must not be laid down on the projecting oil pipe -arrow-.

–  Insert input shaft with input shaft cover in gearbox housing and align according to marks made before removal -arrows-. –  When doing this, rotate input shaft slightly in both directions until all reverse gear clutch plates have engaged.

–  Using a screwdriver -arrow- inserted through opening in housing for ATF filter, rotate gear -1- of intermediate gearing until it engages with gear on input shaft.

–  Check that input shaft cover is flush with gearbox housing. –  After making sure that both components are flush, knock input shaft cover carefully and uniformly into gearbox housing all round as far as stop using a plastic hammer and a suitable piece of wood.   Note

t  If the original input shaft cover and gearbox housing are being reinstalled, use a new circlip -1- of the same thickness as that previously fitted. t  If a new input shaft cover and/or gearbox housing are being installed, you have to determine the thickness of the required circlip.

Determining thickness of circlip -1-

Available circlips - Thickness of circlips in mm
3.035	3.080	3.125

–  First try to fit thickest circlip in groove in gearbox housing. l  The circlip should fit without sticking. l  The circlip must be seated in the bottom of the groove. –  If the circlip cannot be fitted, try to insert the next thinnest circlip; if necessary use the thinnest circlip –  Renew ATF filter → multitronic 0AW, front-wheel drive; Rep. gr.37. –  Fill up with ATF after installing gearbox → Chapter „Filling up with ATF (for ATF purging procedure)“.