From Transmission Build Date 5/25/09

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Reverse Gear Selector Fork -1- Mounted On Selector Shaft With 5th And 6th Gear Selector Fork -2-

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Bearing for reverse gear shift fork:

-- Mount reverse gear shift fork -1- on the selector rod with 5th/6th gear shift fork -2-.

Continuation for all Transmissions

-- Insert differential -1-.

Fig 2: Identifying Differential, Input Shaft & Output Shaft

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NOTE:

A 2nd technician is required for further installation of shafts into clutch housing.

-- As shown in illustration, take output shaft for 1st to 4th gears -3- with selector rods -4- in right hand.

-- Lift differential slightly with the left hand.

-- At the same time, 2nd technician slightly lifts input shaft, output shaft for 5th/6th gears and reverse gear -2- together with reverse shaft.

-- Now, insert the output shaft for 1st to 4th gears in direction of -arrow-.

Places of input shaft, output shafts and final drive gear/differential must engage.

-- Together with a 2nd technician, place the shafts and the differential into their bearing seats.

-- Fasten the 30-211A for the input shaft to the clutch housing.

Fig 3: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE:

For the sake of illustration, clutch housing is depicted rotated 180°.

-- Screw in bolt -A- far enough until input shaft rises slightly.

The grooved ball bearing/input shaft only fits in one position in the transmission housing.

There is a flattened area on the grooved ball bearing and the bearing mount.

If flattened areas -A- and -B- are present, do not insert any spacer washers above and below the grooved ball bearing. Refer to GROOVED BALL BEARING CHANGES .

Fig 4: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008
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Flattened areas -A- on the grooved ball bearing and on bearing mount -B- must align in the transmission housing.

-- Mark the flattened areas with color.

-- Place a marking on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (→ next illustration).

-- Heat the transmission housing using the V.A.G 1416 in the area of the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212° F) for approximately 10 minutes.

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.
Align the marking on the grooved ball bearing -A- with the marking on the transmission housing -B- and mount the transmission housing.

Fig 5: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

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Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

-- Install transmission housing and tighten new bolts -A-, -B- and -C- to tightening specification.

Fig 6: Allocation Of Bolts As Replacement Parts

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Allocation of bolts:

A - Bolt with permanent washer

B -Bolt without washer

C -Bolt with permanent washer

-- Install circlip -1- for grooved ball bearing/input shaft.

Fig 7: Identifying Circlip & Special Tool VW 309

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-- Remove 30-211A for input shaft.

-- If selector shaft lock sleeve has been removed, drive it in now as far as stop on tool LOCK SLEEVE DIFFERENTIATION .

-- Turn transmission with opening for selector shaft in assembly stand upward.

Fig 8: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

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-- Insert selector shaft -1- into lower mounting -2- and into shift forks -3-.

NOTE:

To improve clarity, the cap is removed.

-- Now press selector shaft -1- against lock sleeve -2- direction of -arrow- and guide downward with shift finger -3- through shift forks until stop.

Fig 9: Identifying Selector Shaft Pressed Against Lock Sleeve And Guided Downward With Shift Finger

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Shift cover -4- must stand parallel to bolting surface on transmission housing during this.
Selector shaft must be able to be moved easily in selector motion (up- and downward).

NOTE:

If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.

-- Tighten the bolts -3- for the shift cover -4-.

Fig 10: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Install lock bolt -2-, lock elbow -arrow- must not be installed when doing so.

-- Install back-up light switch -F4- -1-.

-- Install the flange shaft with spring, the thrust washer and tapered ring.

Fig 11: Identifying Installation Of Flange Shaft

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-- Drive input shaft seal in flush.

Fig 12: Driving In Input Shaft Oil Seal Flush

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-- Install the clutch slave cylinder with release bearing. Refer to SLAVE CYLINDER WITH RELEASE BEARING .

-- Shift through all gears.

-- Drive the cap into the transmission housing as far as the stop.

Fig 13: Identifying Tool Assembly To Install Metal Cap On Transmission Housing

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-- Secure the cap with the circlip -A-.

Fig 14: Identifying Transmission Housing Without Sealing Cap Circlip

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Install bevel box in manual transmission as follows:

CAUTION:

Risk of damaging sealing ring between transmission and bevel box.

Place bevel box on transmission together with right flange shaft while turning shaft.

-- With manual transmission, lubricate differential splines with grease for clutch disc shaft splines G 000 100.

-- Slide on bevel box completely on manual transmission, while doing this, join splines of input shaft/bevel box centrally with differential.

-- Bring right drive axle splines and differential bevel gear also into alignment, rotate flanged shaft if necessary.

-- With proper tooth position and central guiding, bevel box slips up to stop against manual transmission.

NOTE:

Do not pull bevel box with mounting bolts against manual transmission, otherwise bevel box is canted and mounting eyelets can break off.

-- Tighten 4 bevel box connecting bolts -arrows- (only 3 shown in illustration) at manual transmission. Tightening specifications -10- FLANGE SHAFT AND SEALS ON BEVEL BOX ASSEMBLY OVERVIEW => Bolt .

Fig 15: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

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-- Install right flange shaft. Refer to FLANGE SHAFT AND SEALS ON BEVEL BOX ASSEMBLY OVERVIEW .