Assembly sequence: Disassembling
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.
- Clamp transmission in VW 540 holding fixture.
- Place container under the transmission.
- Drain gear oil.
- Screw out bolts -1- and detach leaf spring -2-.
- Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-.
- Unbolt guide sleeve.
- Unscrew bearing housing -arrow- and pull off.
Bearing housing is pushed away slightly from end cover by coil spring -A- when it is being pulled off.
- When detaching bearing housing, observe installation position of dished washer -C-.
- Installation position: Outside diameter (concave side) facing shims -B-
- Remove shims -B-, note thickness and re-determine if necessary. Refer to Figure.
- Pull Torsen differential out of end cover.
- Pull oil collector sufficiently far out of end cover -arrow- until it moves freely.
- Swivel oil collector -arrow- down and guide it out through hole of end cover.
- Remove oil collector.
- Remove locking bolts -A- for selector shaft from transmission housing.
- Remove 3 bolts -B- for cover for selector shaft, remove cover.
- Pull out selector shaft.
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates -arrows-.
- Slacken multi-point socket head bolt -arrow B- in input shaft through hole -arrow A- in end cover and unscrew.
- Remove supporting plate.
- Remove supporting plate for needle bearing.
- Remove 2 magnets -arrows A- and clean.
- Slacken 5 bolts -arrows B- for attaching end cover to manual transmission and remove.
- Pull off 2nd inner race of four-point bearing (roller bearing side) for input shaft.
NOTE:
Internal puller 3275 engages in a circular groove in the inner race when pulling off -arrow-.
- Remove end cover together with end cover/bearing plate gasket.
- Pull dowel sleeves out of bearing plate.
Fig 13: Pulling Off Selector Gear For 5th Gear With Spring Together With 1st Inner Race For 4-Point Bearing (Ball Bearing Side) For Input Shaft
- Pull off 5th sliding gear and spring together with 1st inner race -A- of four-point bearing (ball bearing side) for input shaft.
B - Two-arm puller, e.g. Kukko 20/10
- Remove 5th gear synchro-ring.
- Remove circlip for 5th gear wheel.
- Lock hollow shaft in position by engaging two gears. Refer to Fig 9
- Pull off 5th gear wheel.
NOTE:
Only use hexagon bolt of spring sleeve 3116, length 50 mm
C - Two arm puller, e.g. Kukko 20/10 with 200 mm hooks
- Remove shim -B- for 5th gear wheel, note thickness and re-determine if necessary. Refer to Figure.
- Remove spacer sleeve -A-.
- Press out spring pin -A- for selector fork for 5th and 6th gear.
NOTE:
- Do not damage synchro-ring for 6th gear when pressing out spring pin.
- Do not drive out spring pin, otherwise selector rod bearing will be damaged.
- Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (until stop is felt).
- Mark relative positions -arrow 3- of locking collar for 5th and 6th gears -arrow 1- and synchro-hub -A- (paired) -arrow 1-.
- Pull follower together with selector fork and locking collar off selector rod.
Fig 18: Pull Off 6th Gear Selector Gear, 6th Gear Synchronizer Ring, 5th And 6th Gear Synchronizer Hub And Needle Bearing Inner Race For 5th Gear Selector Gear
- Pull off 6th sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th gears and inner race for 5th sliding gear needle bearing.
A - Two-arm puller, e.g. Kukko 20/10 with 200 mm hooks
- Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
- Secure drive pinion opposite hollow shaft e.g. with hose strap, to prevent it slipping out.
- Detach bearing plate with input shaft, drive pinion and hollow shaft and with shift lever mechanism in transmission from transmission housing.
- Remove circlip from selector rod for 1st and 2nd gear and remove follower -A-.
- Pull out selector rod -B- for 5th and 6th gear.
- Remove follower -C- for reverse gear.
- Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft.
- Remove circlip -arrow B- for cylinder roller bearing inner race with pliers.
- Take out inner race -arrow C- for cylinder roller bearing (not a press fit).
- Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing plate.
- Unscrew hexagon bolt -D-, remove spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse idler gear.
- Take out spring, synchro-ring and reverse idler gear.
- Remove relay lever for reverse gear.
NOTE:
- Drive pinion and hollow shaft can be removed complete if it is possible to easily lever off 6th gear wheel.
- If, however, it is necessary to press off 6th gear wheel, the drive pinion must be pulled out from hollow shaft.
- Remove temporary locking element preventing drive pinion from slipping out.
- Pull drive pinion out of hollow shaft -D- collect taper rollers -A- (23 off) when carrying out this step.
- Remove corrugated spring -B- and needle roller assembly -C-.
NOTE:
Carefully protect mount from contamination, clean if necessary.
- Check drive pinion/hollow shaft bearing.
1 - Flange ring (conical contact surface facing taper rollers)
2 - Taper rollers (23 off) with large diameter facing drive pinion head
3 - Supporting ring (conical contact surface facing taper rollers)
4 - Corrugated spring
5 - Circlip for taper roller bearings for drive pinion
- Pressing off 6th gear wheel
NOTE:
Because of the type of fit, it may be possible to press gear off easily.
- Remove hollow shaft or drive pinion and hollow shaft from bearing plate together with selector rod and selector fork for 1st and 2nd gears.