Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion, selector rods and transmission cover, removing and installing

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Disassembly And Assembly

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Special tools and workshop equipment required

VW 309 Holding plate
VW 353 Transmission support
3235 Press Device
3357 Triple square socket driver

VAG 1582 Tapered roller bearing puller
VAG 1582/2 Gripping piece

Special tools and workshop equipment required

Fig 2: Identifying Drip Tray V.A.G 1306

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VAG 1306 Drip tray

Fig 3: Identifying Torque Wrench V.A.G. 1331

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VAG 1331 Torque wrench
Sealant AMV 188 001 02

NOTE:

It is not necessary to remove the differential to remove the above-mentioned components.
Removal is only necessary when adjustments have to be carried out adjustment overview:

Removing

Place drip tray VAG 1306 underneath the transmission.
Drain gear oil, using socket attachment 3357.

Fig 4: Securing Transmission To Assembly Stand

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Secure transmission to repair stand.

Fig 5: Clutch Release Lever Components

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Detach clutch release lever -A- with release bearing.

NOTE: Cover input shaft splines with a shrink-fit hose to protect oil seal, before pulling off guide sleeve.

Remove guide sleeve -B-.
Remove dished washer -C-.
In front of input shaft ball bearing remove circlip -D-.
Note the thickness of the circlip, if the ball bearing, input shaft or transmission housing is not being replaced.

Fig 6: Pulling Input Shaft Ball Bearing Out Of Transmission Housing

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Pull the input shaft ball bearing out of the transmission housing.

Fig 7: Location Of Rear Circlip For Input Shaft Ball Bearing

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Remove the circlip (arrow) behind the input shaft ball bearing.
Note the thickness of the circlip, if the ball bearing, input shaft or transmission housing is not being replaced.

Fig 8: Transmission Cover Installed On Transmission Housing

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Remove transmission cover -A- from transmission housing -B-.

Fig 9: Location Of Multi-Function Sensor

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Remove bolts (arrows) and pull out the multi-function sensor.

Fig 10: Identifying Threaded Bolts At Both Ends Of Relay Shaft

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Remove relay shaft bolts (arrows).

Fig 11: Identifying Shift Detent Fastener

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Remove detent segment (arrow) and swivel it out.

Fig 12: Identifying Input Shaft, Drive Pinion, Relay Shaft, Shift Rods With Selector Shaft And Selector Forks

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The input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector forks -E- must be carefully pulled out together.

Installing

NOTE: If input shaft ball bearing, input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of circlips for input shaft. Refer to Input shaft, adjusting , adjusting input shaft.

Fig 13: Swing Transmission Housing Into Position Shown

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For easier installation of following components, swing transmission housing into the position shown.

Fig 14: Assemble Input Shaft, Drive Pinion, Relay Shaft, Selector Rods With Shift Rod And Selector Forks

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Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector forks -E-.
Install these components together into transmission housing.

NOTE: Relay shaft -C- and selector shaft can also be installed later. Refer to Fig 17.

Fig 15: Identifying Installed Position Of Complete Selector Mechanism In Transmission

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Location of shift mechanism in transmission

1 - Selector fork for 5th gear and reverse gear

2 - Selector fork for 3rd gear and 4th gear

3 - Selector fork for 1st gear and 2nd gear

4 - Relay shaft

5 - Detent mechanism

6 - Selector shaft

NOTE: Shown in illustration with input shaft and drive pinion removed.

Fig 16: Move Transmission To Engage 3rd Gear

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Turn transmission housing and engage 3rd gear (direction of arrow).

Fig 17: Installing Relay Shaft And Shift Rod

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Install relay shaft -A-.

Insert selector shaft -B- sideways into hole in transmission housing and assemble into mounting eye.
Turn the selector shaft in direction of arrow.

Fig 18: Identifying Shift Detent Fastener

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Insert the detent segment and tighten bolt (arrow).

Fig 19: Identifying Threaded Bolts At Both Ends Of Relay Shaft

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Install relay shaft bolts (arrow).
Replace O-ring for multi-function sensor.

Fig 20: Location Of Multi-Function Sensor

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Carefully insert multi-function sensor and tighten (arrow).

Fig 21: Transmission Cover Installed On Transmission Housing

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Check that dowel sleeves for transmission cover -A- are installed in transmission housing -B-.

Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
Install transmission cover onto transmission housing.

Fig 22: Location Of Rear Circlip For Input Shaft Ball Bearing

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Install rear input shaft ball bearing circlip (arrow).
Slide the ball bearing onto input shaft.

Installation position: Closed side of ball cage faces toward transmission housing

Fig 23: Pressing In Ball Bearing

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Press in ball bearing:

Slide thrust pad -A- on press-in tool onto input shaft.
Position press-in tool behind splines for clutch plate.
Install bolts -B- until they make contact.

The bolts bear against the indentations in thrust pad -A-.

Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).

Fig 24: Clutch Release Lever Components

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Install front circlip -D- for the input shaft ball bearing.
Install dished washer -C-.

Installation position: Convex side toward guide sleeve -B-

NOTE: Before installing guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.

Fig 25: Clutch Release Lever Components

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Install guide sleeve -B- for release bearing.
Install clutch release lever -A- and release bearing.