Disassembling 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.

Fig 1: Transmission Mounted On Assembly Stand

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Mount transmission on assembly stand.
Place drip tray V.A.G 1306 under transmission.
Drain transmission oil.

Fig 2: Clutch Release Lever Components

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Remove clutch release lever - A - together with release bearing.
Remove guide sleeve - B -
Remove dished spring - C -.
Remove circlip - D - in front of ball bearing for input shaft.

NOTE:

If the input shaft or transmission housing is not to be replaced, note the thickness of the circlip.

Fig 3: Pulling Ball Bearing For Input Shaft Out Of Transmission Housing

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Pull ball bearing for input shaft out of transmission housing.

Fig 4: Location Of Rear Circlip For Input Shaft Ball Bearing

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Remove circlip - arrow - behind ball bearing for input shaft.

NOTE:

If the input shaft or transmission housing is not to be replaced, note the thickness of the circlip.

Fig 5: Selector Shaft Cover Bolts

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Remove bolts - arrows - and selector shaft cover - A -.

Fig 6: Selector Shaft Locking Bolts

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Remove two locking bolts - 1 - for selector shaft.

Make sure that no gear has been engaged.

Push selector shaft - 2 - into transmission as far as it will go, simultaneously removing pin - 3 -.
Remove selector shaft.

Fig 7: Locating Selector Rods

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Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).

Fig 8: Transmission Cover Securing Bolts

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Remove securing bolts for transmission cover - arrows -.

Fig 9: Transmission Cover, Bearing Housing And Transmission Housing

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Carefully remove transmission cover - A - toward rear. The bearing housing - B - remains installed to transmission housing - C -.

Fig 10: Securing Bearing Housing To Transmission Housing With Two Bolts M8 And Washers

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Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm) and washers.
Tighten 2 bolts - arrows - to max. 5 Nm.
Detach oil collector - A -.

Fig 11: Removing/Installing Multi-Point Socket Head Bolt For Input Shaft

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Check that the 2 gears are still engaged and then unscrew and remove multi-point socket head bolt - 1 - for input shaft.

Fig 12: Detaching 6th Speed Selector Gear With Inner Race For Roller Bearing And Thrust Washer

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Detach 6th speed selector gear with inner race for roller bearing and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10

NOTE:

Check the gear teeth on the selector gears and gear wheels for damage after pulling them off.

Remove synchro-ring and needle bearing for 6th speed selector gear.

Fig 13: Removing 6th Gear Wheel

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Remove 6th gear wheel.

A - Two-arm puller, e.g. Kukko 20/10

Remove spacer sleeve from output shaft.

Fig 14: Identifying Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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Pull out pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -.

Move selector fork - C - downward and detach with locking collar - D -.

Fig 15: Removing 5th Speed Selector Gear Together With Needle Bearing Inner Race For 6th Gear And Synchronizing Hub For 5th And 6th Gear

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Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing hub for 5th and 6th gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

NOTE:

Counter-hold two-arm puller using e.g. open end wrench - B -.
If the needle bearing inner race for 6th gear is in contact with press tool VW 433, insert locking pin 2064 into hole in input shaft to pull off the components all the way.

Fig 16: Remove 4th And 5th Gear Wheels Together

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Remove 4th and 5th gear wheels together.

A - Puller, e.g. Kukko 18/2

NOTE:

Counter-hold puller - A - using e.g. transmission bracket 2004.

Fig 17: Removing 4th Speed Selector Gear With Needle Bearing Inner Race For 5th Gear And Thrust Washer

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Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

Counter-hold two-arm puller using e.g. open end wrench - B -.
Remove synchro-ring and needle bearing for 4th speed selector gear.

Fig 18: Pulling Pin With Clip Securing Selector Fork For 3rd And 4th Gear Out From Selector Rod

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Pull pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -.

Detach selector fork - C - with locking collar - D -.
Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.

Fig 19: Pulling Off 3rd Speed Selector Gear With Synchronizing Hub For 3rd And 4th Gear

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Pull off 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.

A - Puller, e.g. Kukko 18/2

NOTE:

Counter-hold puller - A - using e.g. transmission bracket 2004 to prevent plate T40086 from making contact with 3rd gear wheel or selector rod for 5th and 6th gear.

Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.

Fig 20: Pulling Off Thrust Washer For 3rd Speed Selector Gear

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Pull off thrust washer - B - for 3rd speed selector gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Fig 21: Removing Circlip For 3rd Gear Wheel

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Remove circlip for 3rd gear wheel and note thickness of circlip.
Pull off 3rd gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Fig 22: Reverse Shaft Support Bolts, Bearing Housing And Bolts

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Remove bolts - arrows - for reverse shaft support.
Remove 2 bolts - A - for bearing housing at transmission housing.
Remove bearing housing - B - together with shafts.

Fig 23: Driving Reverse Shaft Support Carefully Out Of Bearing Housing And Removing With Reverse Gear Wheel

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Insert an internal puller - A - e.g. Kukko 21/2 into bore for reverse shaft support.
Spread open internal puller far enough for it to make contact with reverse shaft support - B -.
Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with reverse gear wheel.

Fig 24: Pulling Out Input Shaft From Bearing Housing

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Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.

Fig 25: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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Pull pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -.

Detach selector fork - C - with locking collar - D -.

Fig 26: Pressing Off Synchronizing Hub For Reverse Gear From Output Shaft

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Press off synchronizing hub for reverse gear from output shaft.

NOTE:

Place the bearing housing onto thrust plates VW 401 and VW 402 so that the output shaft and selector rods are not damaged when pressing off the synchronizing hub.

Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.