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 gear 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 -.
Then remove circlip - D - in front of ball bearing for input shaft.

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

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

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

Fig 5: Locating Torsen Housing Bolts

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Remove bolts - arrows - and detach Torsen housing - A -.

NOTE:

The illustration shows only 4 of the 6 securing bolts.

Remove Torsen differential and spring from pinion shaft/hollow shaft.

Fig 6: Selector Shaft Cover Bolts

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

Fig 7: Selector Shaft Locking Bolts

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Remove two locking bolts - 1 - for selector shaft.

Make sure gear has not been engaged.

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

Fig 8: 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 9: Removing Bolts Securing Transmission Cover And Bolts Securing Bearing Housing To Transmission Housing

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

NOTE:

Always replace transmission cover O-ring - arrow -.

Fig 10: Bearing Housing Secured 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 two bolts to max. 10 Nm.
Remove oil collector - A -.

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

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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: Pulling Off 6th Gear Wheel

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Pull off 6th gear wheel.

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

Remove spacer sleeve from hollow 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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Remove 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 thrust pad con. 8/65 VW 433, insert lock pin 2064 into hole in input shaft to pull off the components all the way.

Fig 16: Pulling Off 5th Gear Wheel

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Pull off 5th gear wheel.

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

NOTE:

The 5th gear wheel can also be pulled off together with the 4th gear wheel Fig 17.

Fig 17: Pulling Off 5th Gear Wheel

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Pull off 4th gear wheel.

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

NOTE:

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

Fig 18: 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 19: Pulling Pin With Clip Securing Selector Fork For 3rd And 4th Gear Out From Selector Rod

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Remove 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 -.

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

Fig 20: Pulling Off 3rd Speed Selector Gear With Synchronizing Hub For 3rd And 4th Gear

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Remove 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 holder 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 21: 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 22: Identifying Reverse Shaft Support Bolts, Hose Clip And Bolts Securing Bearing Housing To Transmission Housing

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Remove bolts - arrows - for reverse shaft support.
Prevent pinion shaft from falling out and secure onto hollow shaft using e.g. a hose clip - A -.
Remove two bolts - B - securing bearing housing to transmission housing and detach bearing housing.
Remove hose clip from pinion shaft.

Fig 23: Identifying Needle Bearing For Pinion Shaft And Hollow Shaft

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Remove needle bearing - A - for pinion shaft - B - and pull out pinion shaft from hollow shaft - C -.

Fig 24: 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 hole 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 25: 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 26: Pulling Out Input Shaft From Bearing Housing At An Angle From The Front

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

Fig 27: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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Remove 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 -.

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

Fig 28: Pressing Off Synchronizing Hub For Reverse Gear From Output Shaft

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Press off synchronizing hub for reverse gear from hollow shaft.

NOTE:

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

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