Assembling transmission
WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
If the input shaft or the transmission housing have been replaced, you must first re-determine the thickness of the input shaft circlips → Determining circlips for input shaft ball bearing .
NOTE:
- Lubricate all needle bearings with gear oil before installing.
- Check synchro-rings for wear Checking synchro-ring for wear
- Insert spring in selector gear Inserting spring in selector gear
- Heat gear wheels, needle bearing inner races and synchronizing hubs to 130° C (max.) before pressing on (wear protective gloves).
- Insert output shaft in bearing housing and selector fork for 1st and 2nd gear.
- Place reverse gear selector gear with needle bearing, spring and synchro-ring onto output shaft.
- The lugs on synchro-ring should engage into recesses in selector gear.
- Press on reverse gear synchronizing hub.
- Installation position: high inside collar faces 3rd gear wheel.
- Check axial clearance of reverse selector gear.
Fig 2: Inserting Input Shaft With Needle Roller Bearing Into Bearing Housing At An Angle Toward The Rear
- Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an angle toward the rear.
- Install reverse gear wheel and tighten 3 bolts - arrows - for reverse shaft support to 30 Nm.
Assembly overview - reverse gear wheel Assembly overview - reverse gear wheel
Fig 4: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar
- Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse gear synchronizing hub.
- The markings on locking collar and synchronizing hub - arrow - must coincide.
- The chamfer on locking collar faces reverse selector gear.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
Fig 5: Plate T40088/1 Placed On Press Table And Bearing Housing Inserted With Shafts And Selector Rods
- Place plate T40088/1 on press table and insert bearing housing with shafts and selector rods.
- Press on 3rd gear wheel.
- Installation position: machined side faces reverse gear synchronizing hub.
- Insert circlip for 3rd gear wheel.
- When replacing gear wheel or output shaft:
Re-determine thickness of circlip for 3rd gear wheel:
- Determine thickest circlip that will just fit and install it. For Part No.
The following circlips are available:
| Circlip thickness (mm) | ||
| 1.90 | 1.98 | 2.06 |
| 1.94 | 2.02 | 2.10 |
- Press on thrust washer - A - for 3rd speed selector gear until limit stop.
Fig 8: Installing Needle Bearing For 3rd Speed Selector Gear And Circlip For 3rd Gear Needle Bearing Onto Input Shaft
- Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto input shaft.
- Install 3rd speed selector gear with spring and synchro-ring.
- The lugs on synchro-ring should engage into recesses in selector gear.
- Press on heated synchronizing hub for 3rd and 4th gear
- Installation position: high inside collar faces 3rd speed selector gear.
- Insert circlip for synchronizing hub for 3rd and 4th gear.
- When replacing synchronizing hub or input shaft:
Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
- Determine thickest circlip that will just fit and install it. For Part No.
The following circlips are available:
| Circlip thickness (mm) | ||
| 1.90 | 1.96 | 2.02 |
| 1.93 | 1.99 | 2.05 |
- Check axial clearance of 3rd speed selector gear.
- Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and synchronizing hub for 3rd and 4th gear.
- The markings on locking collar and synchronizing hub - arrow - must coincide.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
NOTE:
- Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm) into selector fork for 3rd and 4th gear.
Fig 12: Installing 4th Speed Selector Gear With Spring, Synchro-Ring, Needle Bearing And Thrust Washer For 3rd And 4th Gear And Pressing On Heated Inner Race For Needle Bearing For 5th Speed Selector Gear
- Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd and 4th gear - B -.
- Press on heated inner race - C - for needle bearing for 5th speed selector gear.
- Check axial clearance of 4th speed selector gear.
- Heat 4th gear wheel and press on.
- Installation position: high inside collar faces 5th gear wheel.
- Heat 5th gear wheel and press on.
- Installation position: high inside collar faces 4th gear wheel.
- Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.
- The lugs on synchro-ring should engage into recesses in selector gear.
- Install and press on heated synchronizing hub for 5th and 6th gear.
- Check axial clearance of 5th speed selector gear.
Fig 16: Identifying Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar
- Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for 5th and 6th gear.
- The markings on locking collar and synchronizing hub - arrow - must coincide.
- Move selector fork for 5th and 6th gear - C - into selector rod - B -.
- If holes of selector fork and selector rod coincide, clip in pin with clip - A -.
- Press on heated inner race for needle bearing for 5th speed selector gear.
- Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A -.
- Heat inner race - B - for needle roller bearing and press on.
- Check axial clearance of 6th speed selector gear.
- Install spacer sleeve - A - onto output shaft.
- Heat 6th gear wheel and press on.
Insert circlip - A - for 6th gear wheel.
- When replacing gear wheel or output shaft:
Re-determine circlip - A - for 6th gear wheel:
- Determine thickest circlip that will just fit and install it. For Part No.
The following circlips are available:
| Circlip thickness (mm) | ||
| 1.90 | 2.02 | 2.14 |
| 1.93 | 2.05 | 2.17 |
| 1.96 | 2.08 | 2.20 |
| 1.99 | 2.11 | |
- Remove bearing housing from holding plate T40088/1.
- Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows - and washers.
- Tighten these 2 bolts - arrows - to max. 5 Nm.
NOTE:
- Do not install oil collector - A - at this stage.
- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).
- Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
- Remove complete bearing housing from transmission housing.
- Check if the 2 dowel sleeves are installed between transmission housing and bearing housing.
- Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between transmission housing and bearing housing.
- Install bearing housing onto transmission housing.
- Clip oil collector - A - into reverse shaft support.
NOTE:
- Make sure that the bolts - arrows - are removed.
- Check if the 2 dowel sleeves are installed between bearing housing - B - and transmission cover - A -.
- Apply sealing paste AMV 188 001 02 evenly and not too thickly onto contact surfaces between bearing housing and transmission cover.
- Insert securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C -.
- Tighten bolts - arrows - to 35Nmplus an additional 90° 1 /4 turn.
- Push assembly sleeve 01E311120 - A - onto selector shaft - B -.
NOTE:
- To avoid damaging the oil seal - C - , the oil seal and selector shaft must only be installed using assembly sleeve 01E311120 - A -.
- Move selector rods to neutral.
- Install complete selector shaft.
- Installation position: Chamfer of selector shaft points downward.
- Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.
- Installation position for pin - 3 - : The groove - arrow - on pin points toward selector shaft cover.
- Clean threads of locking bolts - 1 - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 45 Nm.
- Install cover - A - with new O-ring.
- Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 24 Nm.
- Install rear circlip - arrow - for input shaft ball bearing.
- Then push ball bearing onto input shaft.
Installation position:
The sealed side of ball cage faces transmission housing.
- Pressing in ball bearing:
First screw door hinge alignment tool (M8 and M10) 3114/2 into tapped hole for ball head stud.
Slide thrust plate T10246/2 onto input shaft.
Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - A - only slightly. The bolts locate in recesses in the thrust plate T10246/2.
Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).
- Install front circlip - D - for input shaft ball bearing.
- Install dished spring - C -.
Installation position:
The curved side faces guide sleeve - B -.
- Install a shrink hose onto input shaft splines.
- Install guide sleeve - B - for release bearing.
- Remove shrink hose.
- Install clutch release lever - A - with release bearing.
- Select all gears.