Transmission With CIRCLIP A For The Cap/Input Shaft: Notes

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.

Transmission with Circlip -A-

Fig 1: Identifying Transmission Housing Without Sealing Cap Circlip

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Remove and install the transmission housing, shift mechanism, input shaft, output shafts, differential bevel box, and selector rods.

Special tools and workshop equipment required

Holding Plate VW 309
Holding Fixture VW 313
Transmission Support VW 353
Thrust Tube VW 455
Slide Hammer-Complete Set VW 771
Kukko 21/1 internal puller
Kukko 17/0 separating tool
Kukko 22/1 counter-support
Bracket 30-211A
Thrust piece T10042
Thrust piece T10143
Thrust piece T40008
Torque Wrench V.A.G 1331
Heat Gun V.A.G 1416
Drift T10169
or Drift T10362 LOCK SLEEVE DIFFERENTIATION
Extractor Lever VW 681
Oil Collecting and Extracting Device V.A.G 1782
Socket and Key T10107 A

Removing

Transmission removed, refer to TRANSMISSION, REMOVING and secured to the assembly stand TRANSMISSION, SECURING TO ASSEMBLY STAND .

-- Rotate transmission in assembly stand with oil drain plug downward.

-- Place drip tray underneath.

-- Drain gear oil from manual transmission.

-- Remove the right flange shaft bolt with the T10107 A.

Fig 2: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

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-- Remove 4 bevel box connecting bolts -arrows- (only 3 shown in illustration) at manual transmission.

-- Carefully press bevel box off manual transmission while protecting it against falling through.

-- Remove the clutch slave cylinder with the release bearing -arrows-.

Fig 3: Identifying Slave Cylinder With Release Bearing

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-- In the following step, ensure that the selector shaft is not locked by the lock elbow -arrow-.

Fig 4: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move shift shaft to neutral position.

-- Remove mounting bolt -2-.

-- Remove the bolts -3-.

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

-- Pull selector shaft -4- off transmission housing.

-- Remove the left flange shaft bolt by installing 2 bolts in the flange and counter holding the flange shaft with the assembly lever.

Fig 5: Identifying Installation Of Flange Shaft

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-- Remove bolts -B- inside clutch housing for securing clutch housing to transmission housing.

Fig 6: Identifying Interior Clutch Housing Bolts

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NOTE:

One bolt -arrow- is located outside of bolting flange.

-- Secure the input shaft by inserting the VW 455 over the input shaft, onto the clutch housing.

Fig 7: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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-- Then tension separating tool -A-, for example Kukko 17/0 tightly behind input shaft splines.

Back side of separating tool must contact pressing sleeve free of play.

-- Remove the cap/input shaft circlip -A-.

Fig 8: Identifying Transmission Housing Without Sealing Cap Circlip

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-- Knock rubber through in center of cap -C- using a screwdriver.

Fig 9: Identifying Support, Internal Puller & Cap

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-- Remove cap from transmission housing.

A - Support, for example Kukko 22/1

B - Internal puller 8 to 12 mm, for example Kukko 21/01

Remove circlip -C- from input shaft grooved ball bearing in the following manner:

Fig 10: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

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-- Hold one end of circlip in place using screwdriver -A-.

-- With the 2nd screwdriver -B-, pry the other end of the circlip out of the groove of the grooved ball bearing -arrow-.

-- By repositioning screwdriver -B-, pry the circlip out further.

-- Remove mounting bolts -A- for transmission housing at clutch housing.

Fig 11: Identifying Transmission Housing To Clutch Housing Bolts

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-- Screw adapter VW 771/40 into threaded hole of transmission housing.

Fig 12: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

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-- 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.

-- Pull off transmission housing from clutch housing -arrow- using slide hammer VW 771/1.

NOTE:

If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.

-- Remove separating tool -A- and VW 455 from input shaft.

Fig 13: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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NOTE:

A 2nd technician is required to remove shafts from clutch housing.

-- Lift differential -1- with the left hand.

Fig 14: Identifying Differential & Output Shaft Lifted With Selector Rods

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-- With the right hand, lift output shaft for 1st to 4th gears together with selector rods -2- -arrow A-.

-- At the same time, 2nd technician lifts input-, reverse- and output shaft for 5th/6th gear -3- together with selector rods out of clutch housing -arrow B-.

NOTE:

If necessary, differential can be shifted again in clutch housing after lifting shafts.

-- Pry off the shaft sealing ring for the input shaft with the VW 681.

NOTE:

Grooved ball bearing on input shaft must always be replaced -6- INPUT SHAFT ASSEMBLY OVERVIEW => Grooved Ball Bearing .

Transmission, Assembling

A new grooved ball bearing must be pressed on to input shaft -6- INPUT SHAFT ASSEMBLY OVERVIEW => Grooved Ball Bearing .

-- First insert input shaft -1-, output shaft for 5th/6th gears -2- together with selector rod -3-, shift fork -4- and reverse shaft -5-.

Fig 15: Identifying Input Shaft And Output Shaft For 5th/6th Gears Inserted Together With Selector Rod, Shift Fork And Reverse Shaft

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To transmission build date 5/24/09

Fig 16: Identifying Reverse Gear Selector Fork -1- Mounted On Axle -2- Behind 5th And 6th Gear Selector Shaft -3-

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Bearing for reverse gear shift fork:

-- Mount reverse gear shift fork -1- on axle -2- behind 5th/6th gear selector rod -3-.