Ball bearing for input shaft, multi-function sensor, pinion, selector rods, transmission cover and Torsen differential housing, removing and installing

WARNING: This page is about a different car, the 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.

NOTE:

The differential does not have to be removed in order to remove the above-mentioned components.
Removal is only necessary when adjustment work must be performed. Refer to Adjustment table .

Special tools, testers and other items required

Fig 1: Identifying Triple Square Socket Driver 3357

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Allen key extension 3357

Fig 2: Identifying Special Tools - Disassembly And Assembly

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Special tools and workshop equipment required

VW 309 Holding plate
VW 353 Transmission support
3235 Pressing-in tool
3357 Allen key extension

V.A.G 1582 Tapered roller bearing puller
V.A.G 1582/2 Gripper

Special tools and workshop equipment required

Fig 3: Identifying Drip Tray V.A.G 1306

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V.A.G 1306 Drip tray

Fig 4: Identifying Torque Wrench V.A.G. 1331

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V.A.G 1331 Torque wrench
Sealant AMV 188 001 02

Removing

Place drip tray V.A.G 1306 under transmission.
Drain oil using Allen key extension 3357.

Fig 5: Securing Transmission In Assembly Stand

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Clamp transmission in repair stand.

NOTE:

To protect oil seal, pull shrink down tube over splines of input shaft before pulling off guide sleeve.

Fig 6: Clutch Release Lever Components

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

Make a note of thickness of circlip if not replacing ball bearing, input shaft or transmission housing.

Fig 7: Pulling Input Shaft Ball Bearing Out Of Transmission Housing

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Pull ball bearing of input shaft out of transmission housing.

Fig 8: Location Of Rear Circlip For Input Shaft Ball Bearing

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Remove circlip (arrow) behind input shaft ball bearing.
Make a note of thickness of circlip if not replacing ball bearing, input shaft or transmission housing.

Fig 9: Identifying Cover, Transmission Cover , and Transmission Housing

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Disconnect Torsen differential housing -A- from transmission cover -B-.
Remove spring from pinion.
Remove transmission cover -B- from transmission housing -C-.

Fig 10: Location Of Multi-Function Sensor

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Remove bolts (arrows) and pull out multi-function switch.

Fig 11: Identifying Threaded Bolts At Both Ends Of Relay Shaft

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Remove bolts for guide shaft (arrows).

Fig 12: Identifying Shift Detent Fastener

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Remove screw for detent segment (arrow) and remove segment by swivelling out.

Fig 13: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Shift Rods and Shift Forks

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Carefully pull out input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and selector forks -E- altogether.

Installing

NOTE: If the input shaft ball bearing, the input shaft or the transmission housing have been replaced, first define the thickness of the circlips for the input shaft. Refer to Input shaft, adjusting .

Fig 14: Swing Transmission Housing Into Position Shown

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Swivel transmission housing into position as illustrated. It is then easier to insert components mentioned below.

Fig 15: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Selector Rods and Selector Forks

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Assemble input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and selector forks -E-.
Insert these components in transmission housing altogether.

NOTE: Guide shaft -C- and selector shaft can also be inserted afterward if necessary. Refer to Fig 16 and Fig 18.

Fig 16: Identifying Installed Position Of Complete Selector Mechanism In Transmission

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Position of shift mechanism in transmission

1 - 5th and reverse gear selector fork

2 - 3rd and 4th gear selector fork

3 - 1st and 2nd gear selector fork

4 - Guide shaft

5 - Shifting catch

6 - Selector shaft

NOTE: Shown in illustration without input shaft and pinion.

Fig 17: Move Transmission To Engage 3rd Gear

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Swivel transmission housing and then engage 3rd gear (direction of arrow).

Fig 18: Installing Relay Shaft And Shift Rod

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Insert guide shaft -A-.

Place selector shaft -B- sideways in hole in transmission housing and join to retaining eyelet.
Swivel selector shaft carefully in direction of arrow.

Fig 19: Identifying Shift Detent Fastener

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Insert detent segment and tighten screw (arrow).

Fig 20: Identifying Threaded Bolts At Both Ends Of Relay Shaft

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Install bolts for guide shaft (arrows)
Replace O-ring for multi-function switch.

Fig 21: Location Of Multi-Function Sensor

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Carefully insert multi-function switch and tighten screws (arrows).

Fig 22: Identifying Cover and Transmission Cover

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Check whether dowel sleeves for transmission cover -A- (arrows) are present in transmission housing -B-.
Install transmission cover on transmission housing.

Fig 23: Identifying Cover, Transmission Cover , and Compression Spring

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Check whether dowel sleeves for housing -A- (arrows) are present in transmission cover -B-.
Install spring -C-.
Install Torsen differential housing -A- on transmission cover -B-.

Fig 24: Location Of Rear Circlip For Input Shaft Ball Bearing

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Remove rear circlip (arrow) for input shaft ball bearing.
Push ball bearing onto input shaft.

Installation position: Solid side of ball cage faces transmission housing

Fig 25: Pressing In Ball Bearing

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Press in ball bearing:

Push thrust pad -A- of pressing-in tool onto input shaft.
Position pressing-in tool behind splines for clutch plate.
Pre-load bolts -B-.

Bolts are supported in counterbores of thrust pad -A-

Press ball bearing in as far as it will go by tightening bolts alternately (1/2 turn).

Fig 26: Clutch Release Lever Components

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Install front circlip -D- for input shaft ball bearing.
Mount dished washer -C-.

Installation position: Convex side faces guide sleeve -B-

NOTE:

To protect oil seal, pull shrink down tube over splines of input shaft before pushing on guide sleeve.
Replace guide sleeve together with oil seal and O-ring.

Install new guide sleeve -B- for release bearing.
Install clutch release lever -A- and release bearing.