Transmission Cover

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Special Tools And Workshop Equipment Required

Drift VW 207 C
Thrust Plate VW 402
Punch VW 408 A
Punch VW 411
Thrust Disc VW 412
Tube 28 mm Dia. 210 mm VW 420
Sleeve VW 423
Arbor VW 434
Thrust Ring VW 470
Sleeve VW 472/2
Guide Bolt 10 - 15
Drift Sleeve 40-20
Thrust Pad 3005
Thrust Pad 3062
Extension 3161
Guide Bearing Inst. Tool 3347
Shock Absorber Set T10001
Pulling Hook T20143
Drift T40085
Internal Puller 56 to 110 mm, for example, Kukko 21/89
Counter-Support, for example, Kukko 22/4
Sealing paste AMV 188 001 02
Sealing grease G 052 128 A1
Locking fluid AMV 185 101 A1

Fig 1: Exploded View Of Transmission Cover

Courtesy of AUDI OF AMERICA, LLC

Large Securing Bushing
- For the gearshift shaft
- Removing and installing, refer to Fig 2
- Installed dimension, refer to Fig 3
Securing Bushing
- For the gearshift rail / shift fork
- Removing and installing is currently not possible.
Needle Bearing
- For the output shaft/drive gear mounting
- Removing, refer to Fig 4
- Always replace
- Installing, refer to Fig 5
- Secure after installing with peen, refer to Fig 6
Outer Race/Tapered Roller Bearing
- For mounting the impeller wheel/drive gear in the transmission cover
- Removing, refer to Fig 7
- Installing, refer to Fig 8
Transmission Cover
Oil Fill Plug
- 40 Nm
O-ring
- Installed only on transmissions with a cover / gearshift shaft together with a transmission neutral position sensor -G701- or cap
- Always replace
Cover
- For the gearshift shaft together with a transmission neutral position sensor -G701- or a cap
- Not present on all versions
- Assembly overview, refer to Fig 11
- Selector shaft seal, removing and installing, refer to Fig 12
- Remove the gearshift shaft ball sleeve, refer to Fig 13
- Install the gearshift shaft ball sleeve, refer to Fig 15
Cap
- Not present on all versions
- Replace the O-ring with a cap, use the transmission code to allocate.
Bolt
- 24 Nm
- Steel bolts (M8; 25 mm long)
- Insert with locking fluid AMV 185 101 A1
Transmission Neutral Position Sensor -G701-
- Not present on all versions
- Allocate according to transmission code.
- Replace the O-ring on the transmission neutral position sensor -G701-, allocate according to the transmission code.
Cover
- For the gearshift shaft without a transmission neutral position sensor -G701- or a cap
- Not present on all versions
- Allocate according to transmission code.
- Removing and installing, refer to Fig 9
- Assembly Overview Fig 10
- Selector shaft seal, removing and installing, refer to Fig 12
- Remove the gearshift shaft ball sleeve, refer to Fig 13
- Install the gearshift shaft ball sleeve, refer to Fig 14
Bearing Bushing
- For the 3rd/4th gear gearshift rail / shift fork
- Removing, refer to Fig 16
- Installing, refer to Fig 17
Small Locking Bushing
- For the gearshift shaft
- Removing and installing is currently not possible.
Ventilation Pipe
- Installed dimension: 17.5 mm ± 0.5 mm from the upper edge of the pipe on the housing
- Unclip the transmission breather cap
Cap
- For the transmission ventilation

Fig 2: Identifying Large Locking Bushing

Courtesy of AUDI OF AMERICA, LLC

The gearshift shaft must be removed.
If the transmission is not disassembled, place a cloth in the opening for the gearshift shaft to prevent the locking bushing from falling into the transmission.

-- Remove the large locking bushing using the T40085 toward the inside, in the transmission cover.

-- Install the locking bushing using the T40085 to the installation dimension. Refer to Fig 3.

Fig 3: Checking Large Locking Bushing Installed Dimension

Courtesy of AUDI OF AMERICA, LLC

-- Use a depth gauge -2- to check the installed dimension -a- = 5 +/- 0.2 mm.

Insert the depth gauge on the first shoulder -arrow- of the locking bushing.

Fig 4: Removing Needle Bearing From Transmission Cover

Courtesy of AUDI OF AMERICA, LLC

A - Counter-support, for example, Kukko 22/4

B - Internal puller 56 to 110 mm, for example, Kukko 21/89

Fig 5: Installing Needle Bearing All Way Into Transmission Cover

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Remove peening indentations, if present.

Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards 3062.

-- Secure needle bearing after pressing into transmission cover with peen. Refer to Fig 6.

Fig 6: Securing Needle Bearing Inside Transmission Cover

Courtesy of AUDI OF AMERICA, LLC

-- To peen, use blunt center punch with ball-shaped end (ball 5 mm diameter).

-- Needle bearing is secured with 3 peening marks on circumference every 120° -arrows-.

Pay special attention to the position and the diameter of the peen points:

-a- = 2 mm
Dimension -b- = 3 mm

Fig 7: Pressing Tapered Roller Bearing Outer Race Out

Courtesy of AUDI OF AMERICA, LLC

Fig 8: Installing Outer Race

Courtesy of AUDI OF AMERICA, LLC

Fig 9: Removing & Installing the Gearshift Shaft Cover -A-

Courtesy of AUDI OF AMERICA, LLC

The gearshift shaft is removed.

-- Remove the bolts that attach the cover -A- to the transmission cover.

-- Remove the cover using the VW 420 in direction of -arrow-.

-- Clean the sealing surfaces on the cover and transmission cover.

-- Clean screw threads with a wire brush.

-- Apply the sealing compound AMV 188 001 02 evenly on the sealing surface on the sealing cover.

-- Install the sealing push-in cap while installing the bolts using locking fluid AMV 185 101 A1 and tighten down to the specified torque. Refer to TRANSMISSION .

Fig 10: Gearshift Shaft Cover Assembly Overview