Transmission Without CIRCLIP A For 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 without 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 - 211 A
Thrust piece T10042
Drift T10169
Thrust piece T40008
Torque Wrench V.A.G 1331
Heat Gun V.A.G 1416
Used Oil Collecting and Extracting Device V.A.G 1782
Extractor Lever VW 681
Socket and Extended Bit T10107 A

Disassembling

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 the V.A.G 1782 under the transmission.

-- Drain gear oil from manual transmission.

-- Remove the right flange shaft bolt using 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 bolts -arrows-.

Fig 3: Identifying Slave Cylinder Bolts

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-- Remove the clutch slave cylinder together with release bearing -A-.

-- 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.

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

Fig 8: 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 9: 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 the screwdriver -B-, pry the circlip further out.

-- If present, remove spacer washer -1- from transmission housing -2-.

Fig 10: Identifying Laying Washer Above Grooved Ball Bearing

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If the transmission housing is replaced, check whether the spacer washer needs to be reinstalled, refer to FROM TRANSMISSION BUILD DATE 4.10.06 THROUGH APPROXIMATELY 1.21.08 .

-- Remove bolts -A-.

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 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.

-- Pull off transmission housing from clutch housing -arrow- using 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.

-- If present, remove spacer washer -1- from grooved ball bearing -2-.

Fig 13: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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-- If the transmission housing is replaced, check whether the spacer washer needs to be reinstalled, refer to FROM TRANSMISSION BUILD DATE 4.10.06 THROUGH APPROXIMATELY 1.21.08 .

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

Fig 14: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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

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

Fig 15: 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.

-- Drive out sealing ring for input shaft using sleeve30-21.

NOTE:

Grooved ball bearing on input shaft must always be replaced, refer to item under INPUT SHAFT ASSEMBLY OVERVIEW .

Assembling

Fig 16: Identifying Input Shaft And Output Shaft For 5th/6th Gears Inserted Together With Selector Rod, Shift Fork And Reverse Shaft

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A new grooved ball bearing must be pressed on to input shaft, refer to item under INPUT SHAFT ASSEMBLY OVERVIEW .
Tightening specifications TRANSMISSION HOUSING AND SHIFT MECHANISM ASSEMBLY OVERVIEW .

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

-- Insert differential -1-.

Fig 17: 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 the 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 bracket 30 - 211 A for the input shaft to the clutch housing.

Fig 18: 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.

NOTE:

With some transmissions, there are flattened areas -A- on the input shaft grooved ball bearing and on the bearing mount -B-.

Fig 19: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008

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Check the input shaft grooved ball bearing and the transmission housing

Input shaft grooved ball bearing and transmission housing
Without flattened areas on grooved ball bearing -A- and bearing mount -B- FROM TRANSMISSION BUILD DATE 4.10.06 THROUGH APPROXIMATELY 1.21.08
With flattened areas on grooved ball bearing -A- and bearing mount -B- Figure