Assembly sequence: Assembling
WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
- Install hollow shaft with selector fork and selector rod for 1st and 2nd gear (without follower) into bearing plate.
- Heat 6th gear to approx. 100 ° C and install.
- Installation position: Shoulder toward taper roller bearing
WARNING:
Wear protective gloves!
- Press fully in until zero play.
- Insert taper roller bearing of drive pinion/hollow shaft with multi-purpose grease.
- Arrangement: Refer to Figure
A - Flange ring, taper roller (23 off) and supporting ring
B - Corrugated spring
C - Needle roller assembly
D - Hollow shaft
- Oil needle bearing well.
- Insert drive pinion into hollow shaft and secure with hose strap, to prevent it from slipping down.
- Install relay lever -A- for reverse gear over relay lever bolt. paying attention to pin (for limiting movement of relay lever relevant to synchro-ring).
- Insert reverse idler gear -B- and engage relay lever with groove on reverse idler gear.
- Insert synchro-ring -C-.
- Installation position: Position flat on synchro-ring circumference to face input shaft (not as yet installed) -arrow 1-.
- Insert spring.
- Installation position: Hook single angled end into recess on synchro-ring -arrow 2-. Turn double angled end anti-clockwise and insert into opening on bearing plate -arrow 3-.
- Insert shaft for reverse idler gear -C-.
- Install retaining plate -A-.
- Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate
- Insert spring clasp -B- into locking pins of synchro-ring.
- Replace self-locking nut -D- and tighten to 25 Nm.
- Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into bearing plate.
- Selector fork installation position: Rib toward follower. Refer to Input shaft, drive pinion, hollow shaft and shift lever mechanism in transmission, removing and installing , Item 4-
- Press inner race -arrow C- for cylinder roller bearing onto input shaft.
- Install circlip -arrow B- using pliers.
- Engage recess in follower for reverse gear with the free end of relay lever -arrow A-.
- Slide selector rod for 5th and 6th through follower for reverse gear in direction of -arrow B-.
- Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips.
- Lubricate selector rods and all bearings of input shaft and drive pinion in transmission housing and bearing plate with gear oil.
- Lever used input shaft seal carefully out of transmission housing with VW 681.
- Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 001 02.
- Insert complete bearing plate into transmission housing.
NOTE:
When inserting the complete bearing plate, ensure that the selector rods align with their mounting points.
- Drive in 2 dowel sleeves for bearing plate/transmission housing.
- Tighten bolts in diagonal sequence to 25 Nm.
- Insert locking bolts for selector rods with sealing paste AMV 188 001 02 and tighten to 50 Nm.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Install thrust washer -arrow A- for needle bearing for 6th gear.
- Installation position: Shoulder toward circlip -arrow B-, smooth contact surface to shaft end
- Lubricate needle bearing for 6th sliding gear with gear oil and install.
- Slide on 6th sliding gear with spring and synchro-ring.
- Installation position: The lugs of synchro-ring engage into recesses below in sliding gear.
- Support input shaft with support bridge 30-211 A.
Installation position of 5th and 6th gear synchro-hubs:
- Side with projecting face -arrow 1- faces shaft end.
- The input shaft oil bore -arrow 2- and the synchro-hub oil groove -arrow 3- are aligned.
- Heat synchro-hub for 5th and 6th gears to approx. 100 ° C, install and drive on up to stop.
WARNING:
Wear protective gloves!
- Check 6th sliding gear for axial play.
- Permissible axial play: 0.15 to 0.35 mm
- Align markings -arrow 3- on paired synchro -hub -A- and locking collar for 5th and 6th gears -arrow 1-.
- Install locking collar -arrow 1- with selector fork -arrow 2- onto synchro-hub -A-, and at the same time install follower for 5th and 6th gears -B- onto selector rod -C-.
NOTE:
- Selector fork rib -arrow 2- must face toward shaft end.
- When sliding follower onto selector rod for 5th and 6th gear, note holes for spring pin.
- Press in spring pin -A- flush.
NOTE:
- Do not drive in spring pin, otherwise selector rod bearing will be damaged.
- Mount spring pin groove in direction of force as shown in illustration.
- Re-determine shim for 5th gear wheel:
- Install spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
- When installing circlip, press indirection of arrow until fully home.
- Measure size between sleeve and installed circlip using depth gauge -B-.
The following shims are available
| Measured range (mm) | Shim thickness (mm) |
| 31.01 to 31.11 | 1.05 |
| 31.11 to 31.21 | 1.15 |
| 31.21 to 31.31 | 1.25 |
| 31.31 to 31.41 | 1.35 |
- Install selected size of shim -arrow- onto hollow shaft.
- Heat 5th gear to approx. 100 ° C, install and drive on up to stop.
- Installation position: Shoulder toward spacer sleeve
WARNING:
Wear protective gloves!
- Re-determine circlip for 5th gear wheel:
- Determine and attach the thickest 2nd circlip that will still just fit.
Available circlips
| Circlip thickness (mm) | ||
| 2.32 | 2.40 | 2.48 |
| 2.34 | 2.42 | 2.50 |
| 2.36 | 2.44 | |
| 2.38 | 2.46 | |
- Install circlip.
- Drive on inner race for 5th sliding gear free of axial play.
- Oil needle bearing with gear oil and install.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th sliding gear with spring.
Fig 22: Installing 1st Inner Race For Four-Point Bearing For Input Shaft Onto Input Shaft And Drive On Up To Stop
- Heat 1st inner race for four-point bearing (ball bearing side) for input shaft to approx. 100 ° C, install onto input shaft and drive on up to stop.
WARNING:
Wear protective gloves!
- Check 5th sliding gear for axial play.
- Permissible axial play: 0.15 to 0.35 mm
- Insert dowel sleeves into bearing plate.
- Install new gasket for end cover.
- Install end cover and insert securing bolts -arrows B-.
NOTE:
Do not tighten bolts at this stage.
- Clean 2 magnets -arrow A- and insert.
- Insert supporting plate. Refer to Figure and tighten by hand.
- Installation position: Lugs face magnets.
- Tighten bolts for end cover in diagonal sequence.
- Lubricate 2nd inner race for four-point bearing (roller bearing side) and insert onto input shaft with track for ball facing four-point bearing of input shaft and drive over hole in end cover.
- Remove support bridge 30-211 A.
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates -arrows-.
- Tighten multi-point socket head bolt to 150 Nm.
- Check neutral position of followers.
- Gear gates must align.
- Use screwdriver to unclip cover for oil collector -3- from oil collector -1- at long end and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
- Guide oil collector, with supporting arm ahead, from interior of end cover through hole of end cover sufficiently far -arrow-, so that the new O-ring can be installed onto oil collector from outside.
- Lightly oil new O-ring and insert.
- Insert oil pipe of oil collector in input shaft.
- Rotate oil collector until positioning segment is positioned in milled recess of end cover -arrow-.
- Press in oil collector onto stop.
- Slide assembly sleeve -A-, Part No. 01E 311 120, onto selector shaft -B-.
- Install complete selector shaft.
- Installation position: Flat of selector shaft faces downward
- Insert locking bolts -A- for selector rod with sealing paste AMV 188 001 02 and tighten to 50 Nm.
- Lightly oil new O-ring for selector shaft cover and install.
- Install cover for selector shaft.
- Install bolts -B- (x 3) with sealing paste AMV 188 001 02 and tighten to 25 Nm.
- Push Torsen differential onto splines of hollow shaft.
- Press Torsen differential in direction of arrow; measure distance between top edge of bolted end cover and front edge of outer race of ball bearing for Torsen differential.
- Determine shim(s) required according to table.
The following adjustment shims are available:
| Measured range mm | Qty. | Shim thickness (mm) |
| 7.05 to 7.30 | 1 1 1 |
1.65 1.45 1.20 |
| 7.30 to 7.55 | 1 1 1 |
1.65 1.45 0.95 |
| 7.55 to 7.80 | 1 1 1 |
1.65 1.45 0.70 |
| 7.80 to 8.05 | 1 1 1 |
1.65 1.45 0.45 |
| 8.05 to 8.25 | 2 | 1.65 |
| 8.25 to 8.50 | 1 1 |
1.65 1.45 |
| 8.50 to 8.75 | 1 1 |
1.65 1.20 |
| Measured range mm | Qty. | Shim thickness (mm) |
| 8.75 to 9.00 | 1 1 |
1.65 0.95 |
| 9.00 to 9.25 | 1 1 |
1.65 0.70 |
| 9.25 to 9.50 | 1 1 |
1.65 0.45 |
- Insert dished washer -C- into bearing housing.
- Installation position: Large diameter (concave side) facing shims
- Install shims determined from table -B-.
- Install spring -A- onto end of flanged shaft.
- Lightly oil new O-ring for bearing housing and insert.
- Oil small needle bearing in drive pinion.
- Insert complete bearing housing and pre-tighten evenly.
- Tighten bolts in diagonal sequence.
- Pack space between sealing lip and dust lip of new seal for input shaft with sealing grease.
- Pull a thin protective hose tightly onto splines of input shaft.
- Tap in input shaft seal.
- Insertion depth: 3.5 mm
NOTE:
Insertion depth for repairs is 4.5 mm when a used input shaft is employed.
- Remove protective hose.
- Install release bearing, clutch release lever and guide sleeve. Refer to Clutch release mechanism, servicing .
- Select all gears.
- Install connecting rod.
- Top off manual transmission with gear oil and check oil level. Refer to Transmission oil level, checking .