From transmission build date 4.10.06 through approximately 1.21.08

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.

One spacer washer is inserted above and below the input shaft grooved ball bearing, refer to item 6 under INPUT SHAFT ASSEMBLY OVERVIEW .

Upper spacer washer	Outer circumference	78.6 mm
Lower spacer washer	Outer circumference	85 mm

Fig 1: Identifying Measurement Of Shoulder Above Grooved Ball Bearing Mount

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Shoulder Above Grooved Ball Bearing	Dimension "a"	Upper Spacer Washer
Through transmission build date 09 04 6	10 mm	No
From transmission build date 10 04 6	10.7 mm	Yes

Fig 2: Identifying Bearing Seat

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Area Below the Bearing Seat		Lower Spacer Washer
Through transmission build date 09 04 6	Not deeper.	No
From transmission build date 10 04 6	Slightly deeper.	Yes

-- Place a spacer washer (85 mm outer circumference) -1- on grooved ball bearing -2-.

Fig 3: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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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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Do not place any spacer washers above and below the grooved ball bearing.
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 hot air blower 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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Continuation for all transmissions

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

-- 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

-- If a spacer washer was mounted on the grooved ball bearing before installation of the transmission housing, a spacer washer -1- (outer diameter = 78.6 mm) must also be installed after installation of transmission housing -2-, refer to FROM TRANSMISSION BUILD DATE 4.10.06 THROUGH APPROXIMATELY 1.21.08 .

Fig 7: Identifying Laying Washer Above Grooved Ball Bearing

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

Fig 8: Identifying Circlip & Special Tool VW 309

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-- Remove 30 - 211 A for input shaft.

-- If lock sleeve for selector shaft has been removed, drive it in now using T10169 until tool makes contact.

Fig 9: Drive In Lock Sleeve With Shoulder As Far As Stop On Tool

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

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

Fig 10: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

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NOTE:

To improve clarity, the cap is removed.

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

Fig 11: 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 12: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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

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

-- Install left flange shaft. Refer to FLANGE SHAFT AND SEALS ON TRANSMISSION ASSEMBLY OVERVIEW .

-- Drive in the input shaft sealing ring.

Fig 13: 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 cap into transmission housing to stop of T10042

Fig 14: Driving Cap Into Transmission Housing To Stop Of Thrust Piece T10042

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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.

-- 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, refer to item 10 under FLANGE SHAFT AND SEALS ON BEVEL BOX ASSEMBLY OVERVIEW .

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 .