Audi Workshop Service and Repair Manuals

Exploded view - servicing gearbox cover

Special tools and workshop equipment required

t	Drift -VW 207 C-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Press tool -VW 412-

t	Tube -VW 420-

t	Tube -VW 423-

t	Thrust piece -VW 434-

t	Thrust pieces for pinion shaft bearing -VW 470-

t	Sleeve -VW 472/2-

t	Guide pin -10 - 15-

t	Press tool -40 - 20-

t	Thrust plate -3005-

t	Thrust pad -3062-

t	Extension -3161-

t	Assembly tool -3347-

t	Shock absorber set -T10001-

t	Extractor tool -T20143-

t  Drift -T40085-

t  Internal puller 56 ... 110 mm, e.g. -Kukko 21/89- t  Counter-support, e.g. -Kukko 22/4- t  Sealing paste -AMV 188 001 02- t  Sealing grease -G 052 128 A1- t  Locking fluid -AMV 185 101 A1-

1 -	Large locking bush

q	For selector shaft

q	Removing and installing → Fig.

q	Installation depth → Fig.

2 -	Locking bush

q	For selector plate / selector fork

q	At present there is no provision for removing and installing

3 -	Needle bearing

q	Bearing for spur gear drive output gear

q	Pulling out → Fig.

q	Always renew

q	Driving in → Fig.

q	Peen to secure after installing → Fig.

4 -	Tapered roller bearing outer race

q	Bearing for spur gear drive input gear in gearbox cover

q	Pressing out → Fig.

q	Pressing in → Fig.

5 -	Gearbox cover

q	Select correct version according to gearbox code letters → Electronic parts catalogue

6 -	Oil filler plug

q

40 Nm

7 -

O-ring

q	Only installed in gearboxes with sealing cap/selector shaft in conjunction with gearbox neutral position sender -G701- or sealing plug

q	Always renew

8 -	Sealing cap

q	For selector shaft in conjunction with gearbox neutral position sender -G701- or sealing plug

q	Not fitted on all versions

q	Select correct version according to gearbox code letters → Electronic parts catalogue

q	Exploded view → Fig.

q	Removing and installing oil seal for selector shaft → Fig.

q	Removing ball sleeve for selector shaft → Fig.

q	Installing ball sleeve for selector shaft → Fig.

9 -	Sealing plug

q	Not fitted on all versions

q	Select correct version according to gearbox code letters → Electronic parts catalogue

q	Renew O-ring on sealing plug; select correct version according to gearbox code letters → Electronic parts catalogue

10 -

Bolt

q

24 Nm

q	Steel bolts (M8; 25 mm long)

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

11 -	Gearbox neutral position sender -G701-

q	Not fitted on all versions

q	Select correct version according to gearbox code letters → Electronic parts catalogue

q	Renew O-ring on gearbox neutral position sender -G701-; select correct version according to gearbox code letters → Electronic parts catalogue

12 -	Sealing cap

q	For selector shaft without gearbox neutral position sender -G701- or sealing plug

q	Not fitted on all versions

q	Select correct version according to gearbox code letters → Electronic parts catalogue

q	Removing and installing → Fig.

q	Exploded view → Fig.

q	Removing and installing oil seal for selector shaft → Fig.

q	Removing ball sleeve for selector shaft → Fig.

q	Installing ball sleeve for selector shaft → Fig.

13 -	Bearing bush

q	For 3rd/4th gear selector plate / selector fork

q	Pressing out → Fig.

q	Pressing in → Fig.

14 -	Small locking bush

q	For selector shaft

q	At present there is no provision for removing and installing

15 -	Breather pipe

q	Installation depth: 17.5 mm ± 0.5 mm below top of pipe to housing

q	Clip in cap for gearbox breather

16 -

Cap

q	For gearbox breather

Removing and installing large locking bush -1- for selector shaft l  The selector shaft must be removed. l  If the gearbox has not been dismantled, put a cloth in the aperture for the selector shaft to stop the locking bush from dropping into the gearbox. –  Drive out large locking bush inwards (i.e. into gearbox cover) using drift -T40085-. –  Drive in locking bush to correct installation depth → Fig. using drift -T40085-.

Installation depth of large locking bush -1- in gearbox cover –  Check installation depth -a- = 5 ± 0.2 mm using depth gauge-2-. l  Apply depth gauge to first shoulder -arrow- of locking bush.

Pulling needle bearing out of gearbox cover A -  Counter-support, e.g. -Kukko 22/4- B -  Internal puller 56 ... 110 mm, e.g. -Kukko 21/89-

Driving in needle bearing onto stop in gearbox cover   Note Eliminate peening depressions if necessary. Install needle bearing so the lettering (side with thicker metal) faces towards the thrust pad -3062-. –  Secure needle bearing after pressing in by peening into gearbox cover → Fig..

Securing needle bearing in gearbox cover by peening –  Use blunt punch with ball-shaped end (ball Ø approx. 5 mm) to peen in position. –  The needle bearing is secured with 3 peening positions spaced 120° apart around the circumference -arrows-. Observe position and Ø of peening positions: t  Dimension -a- = 2 mm t  Dimension -b- = 3 mm

Pressing tapered roller bearing outer race out of gearbox cover

Pressing tapered roller bearing outer race into gearbox cover (press onto stop)

Removing and installing sealing cap -A- for selector shaft l  Selector shaft is removed. –  Remove bolts securing sealing cap -A- to gearbox cover. –  Carefully knock out sealing cap in direction of -arrow- using tube -VW 420-. –  Clean sealing surfaces of sealing cap and gearbox cover. –  Clean threads of bolts with a wire brush. –  Apply sealing paste -AMV 188 001 02- evenly to sealing surface between sealing cap and gearbox cover. –  Install sealing cap; to do so, fit bolts with locking fluid -AMV 185 101 A1- and tighten to specified torque → Item.

Exploded view - sealing cap for selector shaft 1 -  Oil seal for selector shaft; removing and installing → Fig. 2 -  Sealing cap 3 -  Ball sleeve for selector shaft; removing → Fig., installing → Fig.

Exploded view - sealing cap for selector shaft with aperture -arrow- for gearbox neutral position sender -G701- or sealing plug 1 -  Oil seal for selector shaft; removing and installing → Fig. 2 -  Sealing cap 3 -  Ball sleeve for selector shaft; removing → Fig., installing → Fig. 4 -  O-ring

Removing and installing oil seal for selector shaft –  Prise out oil seal with extractor tool -T20143/1-. –  Lightly oil outer circumference of oil seal. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Drive in oil seal using -T10001/1- or tube -VW 423-. l  Installation depth: 2 mm below top edge of sealing cap

Pressing ball sleeve for selector shaft out of sealing cap

Pressing ball sleeve -A- for selector shaft into sealing cap -B- (press in until flush) Fit ball sleeve so that side with lettering (thicker metal) faces guide pin -10 - 15-.

Pressing ball sleeve -A- for selector shaft into sealing cap -B- (press in to dimension -x-) Fit ball sleeve so that side with lettering (thicker metal) faces guide pin -10 - 15-. l  Installation depth -x- = 2.5 ± 0.5 mm

Pressing bearing bush for 3rd/4th gear selector plate / selector fork out of gearbox cover

Pressing bearing bush -A- for 3rd/4th gear selector plate / selector fork into gearbox cover (press onto stop) –  Insert shoulder -arrow 1- of extension -3161- into bearing bush -A-. –  Insert shoulder -arrow 2- of drift -VW 207 C- in extension -3161- and press in bearing bush onto stop.