Transmission Cover, Servicing

Special tools and workshop equipment required 

• Seal Installer - Crankshaft VW204B
• Bearing Installer - Bearing Press Piece VW207C
• Press Piece - Rod VW408A
• Press Piece - Rod VW411
• Press Piece - Multiple Use VW412
• Press Piece - 28x210mm VW420
• Press Piece - Shift Rod/Alternator VW423
• Press Piece - Bushing VW434
• Press Piece - Multiple Use - Sleeve VW472/2
• Press Piece - Multiple Use VW512
• Guide Pins 10-15
• Bearing Installer - Differential Bearing 40-21
• Press Piece - Multiple Use 3005
• Puller - Transmission Bearing 3138
• Shoulder Piece 3161
• Bearing Installer - Control Arm 3346
• Bearing Installer - Multiple Use 3347
• Shock Absorber Set T10001
• Bearing Installer - Taper Roller Bearing T40103

Fig 1: Identifying Large Locking Bushing

Courtesy of AUDI OF AMERICA, LLC

• The gearshift shaft must be removed.
• If the transmission is not disassembled, place a cloth in the opening for the gearshift shaft to prevent the locking bushing from falling into the transmission.

-- Remove the large locking bushing inward in the transmission cover using the Locking Bushing Drift T40085.

-- Press in the locking bushing to the installation dimension using the Locking Bushing Drift T40085. Refer to Fig 2.

Fig 2: Checking Large Locking Bushing Installed Dimension

Courtesy of AUDI OF AMERICA, LLC

-- Position the Digital Depth Gauge VAS6087 on the first shoulder -arrow- of the locking bushing and check the installed dimension -a-.

Installed dimension -a- :

Transmissions with Transmission Range Gear Recognition Switch -F208- through MY 2012

• 5.0 ± 0.2 mm

Transmissions with Gear Recognition Sensor -G604- from MY 2013.

• 6.5 ± 0.2 mm

• The transmission cover must be removed.

-- Remove the locking bushings for the gearshift rails/shift forks -arrows- using the Drift T10325.

Fig 3: Removing Securing Bushings For The Shift Rails/Shift Forks

Courtesy of AUDI OF AMERICA, LLC

-- Install the locking bushings for the gearshift rails/shift forks -arrows- using the Drift T10326 until it stops in the output shaft.

Fig 4: Pressing In Securing Bushings For The Shift Rails/Shift Forks

Courtesy of AUDI OF AMERICA, LLC

Install needle bearings with the labeled side (side with thicker metal) facing towards Seal Installer - Crankshaft VW204B.

Fig 5: Installing Needle Bearings With Lettering On Bearing Facing Towards

Courtesy of AUDI OF AMERICA, LLC

-- Secure needle bearing after pressing into transmission cover with peen. Refer to Fig 6.

-- To peen, use blunt center punch with ball-shaped end (ball 5 mm diameter).

-- Needle bearing is secured with 4 peening marks on circumference every 90° -arrows-.

Fig 6: Needle Bearing Is Secured With 4 Peening Marks On Circumference Every 90Degrees

Courtesy of AUDI OF AMERICA, LLC

Pay special attention to the position and the diameter of the peen points:

• Dimension -a- = 2 mm
• Dimension -b- = 3 mm.

Fig 7: Identifying Pressing Tapered Roller Bearing Outer Race Out From Transmission

Courtesy of AUDI OF AMERICA, LLC

Fig 8: Identifying Installing Outer Race / Tapered Roller Bearing All Way Into Transmission

Courtesy of AUDI OF AMERICA, LLC

Fig 9: Identifying Removing Input Shaft Roller Sleeve From Transmission

Courtesy of AUDI OF AMERICA, LLC

Fig 10: Identifying Installing Input Shaft Roller Sleeve -A- All Way Into Transmission

Courtesy of AUDI OF AMERICA, LLC

• Mount the roller sleeve with the shoulder in the open side of the Bearing Installer - Control Arm 3346.

Fig 11: Removing & Installing Gearshift Shaft Cover -A-

Courtesy of AUDI OF AMERICA, LLC

• The gearshift shaft is removed.

-- Remove the bolts that attach the cover -A- to the transmission cover.

-- Carefully install the cap using the Press Piece - 28x210mm VW420 -direction of the arrow-.

-- Clean the sealing surfaces on the cover and transmission cover.

-- Apply the Sealing Compound AMV 188 001 02 evenly and secure the cap with new bolts, refer to -item  11- Bolt (See Figure).

Fig 12: Gearshift Shaft Cover Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. Selector Shaft Seal, Removing and Installing. Refer to Fig 14
2. Cap
3. Gearshift Shaft Ball Sleeve. For removing, refer to Fig 15. For installing, refer to Fig 16.

Fig 13: Assembly Overview - Gearshift Shaft Cover With A Hole -Arrow- For Transmission Neutral Position Sensor -G701- Or Cap

Courtesy of AUDI OF AMERICA, LLC

1. Selector Shaft Seal, Removing and Installing. Refer to Fig 14
2. Cap
3. Gearshift Shaft Ball Sleeve, Removing. Refer to Fig 15 and Installing. Refer to Fig 17
4. O-Ring

Fig 14: Gearshift Shaft Seal, Removing & Installing

Courtesy of AUDI OF AMERICA, LLC

-- Pry out shaft seal with Pulling Hook T20143/1.

-- Lightly coat the outer circumference of the shaft seal with oil.

-- Fill the space between the sealing and dust lip halfway with Sealing Grease G 052 128 A1.

-- Install shaft seal with Shock Absorber Set - Socket T10001/1 or Press Piece - Shift Rod/Alternator VW423.

• Installed dimension: 2 mm under the upper edge of the cover

Fig 15: Removing Gearshift Shaft Ball Sleeve

Courtesy of AUDI OF AMERICA, LLC

Fig 16: Installing Gearshift Shaft Ball Sleeve

Courtesy of AUDI OF AMERICA, LLC

Set ball sleeve in place with labeled side (side with thicker metal) facing toward Guide Pins 10-15.

Fig 17: Identifying Gearshift Shaft Ball Sleeve Installed Dimension

Courtesy of AUDI OF AMERICA, LLC

Set ball sleeve in place with labeled side (side with thicker metal) facing toward Guide Pins 10-15.

• Installed dimension -x- = 2.5 ± 0.5 mm

Fig 18: Identifying Removing Bearing Bushing For 3Rd & 4Th Gear Gearshift Rail

Courtesy of AUDI OF AMERICA, LLC

Fig 19: Identifying Installing Bearing Bushing -A- For 3Rd & 4Th Gear Gearshift Rail

Courtesy of AUDI OF AMERICA, LLC

-- Install the Shoulder Piece 3161 with shoulder -arrow 1- in the bearing bushing -A-.

-- Install the bearing bushing all the way using the Bearing Installer - Bearing Press Piece VW207 C while inserting the shoulder -arrow 2- into the Shoulder Piece 3161.