General Repair Information: Components

Transmission

• Allocate bolts and other components according to transmission code.
• Thoroughly clean all connections and the surrounding area before disconnecting.
• When replacing or repairing a manual transmission, check the fluid level and fill if necessary. Refer to General Information .
• Use the transmission code to determine capacities and specifications. Refer to Specifications .

Sealant 

• Thoroughly clean housing joint surfaces before applying sealing compounds.
• Apply sealing paste AMV 188 001 02 evenly and not too thick.
• Do not allow sealing compound to enter ventilation openings.

O-Rings, Shaft Seals, Seals 

• O-rings, shaft seals and seals must be replaced.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Thoroughly clean housing joint surfaces before assembling.
• Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with sealing grease G 052 128 A1.
  Fig 1: Identifying Oil Seals Sealing Lips

  Courtesy of AUDI OF AMERICA, LLC
• The open side of the shaft seals point toward the fluid to be sealed in.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
• After replacing seals and sealing rings, check transmission fluid level and top off if necessary. Refer to General Information .

Fasteners 

• Do not stretch the circlips.
• Installed position for some of the circlips: the circlip is narrower at the top. This makes it easier for the pliers to grab the circlip when removing and installing it.
  Fig 2: Identifying Circlip & Pliers

  Courtesy of AUDI OF AMERICA, LLC
• Always replace damaged or over-stretched circlips.
• Circlips must locate properly in the groove.
• Replace spring pins. Installed position: the slit -A- should be in line with the line of force -arrow-.
  Fig 3: Identifying Locking Elements

  Courtesy of AUDI OF AMERICA, LLC

Bolts and nuts 

Fig 4: Identifying Nut And Bolt

Courtesy of AUDI OF AMERICA, LLC

• Loosen bolts and nuts in reverse of tightening sequence.
• Nuts and bolts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.
• Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Apply locking fluid AMV 185 101 A1 before reinstalling.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (for example, with a thread tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Adjusting Shims 

• Use a micrometer to measure the shims at several points. Tolerance variations make it possible to find the exact shim thickness required.
  Fig 5: Measuring Shim Thickness

  Courtesy of AUDI OF AMERICA, LLC
• Check for burrs and damage.
• Do not install shims which are damaged or not in perfect condition.

Mount 

• Set needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward drift.
• Insert all the bearings in transmission with gear oil.
• Heat inner races of tapered roller bearings to approximately 100 °C (212 °F) with the inductive heat unit VAS 6414 before installing. Press on to the stop when installing, so there is no axial clearance.
• Warm inner race for needle and roller bearings to 130 °C (266 °F) max.
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
• Tapered roller bearings installed on a shaft must be replaced as a set and use same make of bearings.

Gears, synchronizer hubs, selector gear inner races 

• To install, heat gear wheel inner race to approximately 100 °C (212 °F) with VAS 6414.
• Heat the gear wheels and synchronizer hubs to approximately 100 °C (212 °F) with the VAS 6414 before installing. Press on to the stop when installing, so there is no axial clearance.
• Observe installation position.

Selector Gears 

• After assembly, check selector gears of 1st through 6th gear for axial play of 0.15 to 0.50 mm and ease of movement.

Input Shaft 

• If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel -arrow-, then replace both the input shaft and the needle bearing. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING, SACHS AND LUK .
  Fig 6: Checking Input Shaft For Wear

  Courtesy of AUDI OF AMERICA, LLC

• Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate if necessary. Refer to the appropriate service information .
  Fig 7: Checking Input Shaft For Wear

  Courtesy of AUDI OF AMERICA, LLC

Synchronizer Rings 

• Do not interchange. When reusing synchronizer rings, always install to the same gear wheel.
• Check for wear and replace if necessary.
• Coat with gear oil before installing.

Check the Synchronizer Rings Coated with Molybdenum Grease.

Fig 8: Checking Synchronizer Rings Coated With Molybdenum Grease

Courtesy of AUDI OF AMERICA, LLC

• Clean the synchronizer ring. There must not be any oil on the friction surface.
• The friction surface of a intact molybdenum coated synchronizer ring looks graphite gray and slightly porous.
• Replace the synchronizer ring if the friction surface has shiny spots -A- or if the brass color base starts to show through.

Synchronizer Rings for 1st and 2nd Gears:

• Check coated friction surfaces -arrows 2- from intermediate ring -B- for damage (flat areas, disintegrating areas or carbon layer).
  Fig 9: Checking Coated Friction Surfaces From Intermediate Ring For Damage (Flat Areas, Disintegrating Areas Or Carbon Layer)

  Courtesy of AUDI OF AMERICA, LLC
• Check the inner friction surface -arrow 1- of the synchronizer ring -A- and the outer friction surface -arrow 4- of the inner race -C- for grooves and scoring.
• On inner races -C- with coated friction surfaces -arrow 3-, check coating for damage (disintegrating carbon layer).

Damage on the Selector Gears and Locking Collars 

Fig 10: Identifying Damage To Synchronizer Ring Or Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

• Damage to the synchronizer ring or gear wheel:

A - Worn clutch spline camber on the synchronizer ring or gear wheel

• Compare: synchronizer ring or gear wheel not damaged:
  Fig 11: Identifying Synchronizer Ring Or Gear Wheel Not Damaged

  Courtesy of AUDI OF AMERICA, LLC

B - Undamaged clutch spline camber on the synchronizer ring or gear wheel

• Picture of damage on the locking collar:
  Fig 12: Identifying Damage On Locking Collar

  Courtesy of AUDI OF AMERICA, LLC

C - Worn longitudinal inner spline camber and the locking collar

• Comparison: locking collar not damaged:
  Fig 13: Identifying Locking Collar Undamaged

  Courtesy of AUDI OF AMERICA, LLC

D - Undamaged longitudinal inner spline camber and the locking collar

• Synchronizer rings coated with carbon must be replaced together with the locking collar. The gear wheels must be replaced as well depending on the amount of wear.