Spur gear unit, removing and installing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Sealant

Removing

Remove engine → Engine, removing .
Separate engine and transmission → Engine and transmission, separating .
Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand → Engine, securing to assembly stand .
Remove clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

Remove dual-mass flywheel → Dual-mass flywheel, removing and installing .
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove oil filter housing → Oil filter housing, removing and installing .

Remove lower timing chain cover → Lower timing chain cover, removing and installing .
Remove power-steering pump from cylinder block.
Remove power take-off drive chain → Power take-off drive chain, removing and installing .

Fig 1: Removing Bolts & Spur Gear Unit Rear Bearing Cap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 to 8 -.
Remove spur gear unit rear bearing cap.

Fig 2: Removing/Installing Spur Gears

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove spur gears in sequence - 1 to 3 -.

Fig 3: Removing/Installing Compression Spring From/To Shaft For Drive Spur Gear, O-Rings, Bolts & Front Bearing Cap From Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove compression spring - 1 - from shaft for drive spur gear.
Remove O-rings - 2 -.
Remove bolt - arrow -.
Remove front bearing cap from cylinder block.

Fig 4: Removing Drive Shaft For Oil Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove drive shaft - arrow - for oil pump.

Installing

NOTE:

Replace seals and O-rings.

Fig 5: Driving Out Sealing Rings (For A/C Compressor Drive) And (For Power-Steering Pump Drive) Using Drift

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive out sealing rings - 2 - (for A/C compressor drive) and - 3 - (for power-steering pump drive) using a drift.
Remove O-ring - 1 -.
Remove sealant residue on front bearing cap and on cylinder block.
Clean sealing surfaces, they must be free of oil and grease.

Drive in sealing ring for power-steering pump drive and A/C compressor drive → Seals for power take-off, replacing .

Fig 6: Removing Drive Shaft For Oil Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert drive shaft - arrow - for oil pump into guide on oil pump.

NOTE:

To guarantee that the drive shaft engages correctly in oil pump, insert drive shaft only into oil pump, do not install together with front bearing cap.

Fig 7: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1 mm).

Fig 8: Applying Sealant Beads On Clean Sealing Surfaces Of Front Bearing Cap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant beads - arrows - on clean sealing surfaces of front bearing cap as shown in illustration.

Thickness of sealant beads: 1.5 to 2.0 mm.

Install O-ring - 1 - and secure using some grease.

NOTE:

The bearing cap must be installed within 5 minutes after application of sealant.

Fig 9: Removing/Installing Compression Spring From/To Shaft For Drive Spur Gear, O-Rings, Bolts & Front Bearing Cap From Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install front bearing cap and tighten bolt - arrow - hand-tight.
Insert compression spring - 1 -.
Install O-rings - 2 - and secure using some grease.

Fig 10: Removing/Installing Spur Gears In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert spur gears - 1 to 3 -.

Fig 11: Sliding Dust Seal Cap Onto Shaft End Of A/C Compressor Drive Spur Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide dust seal cap - arrow - onto shaft end of A/C compressor drive spur gear.
Check whether 2 alignment bushings are present in rear bearing cap, install if necessary.

Fig 12: Locating Rear Bearing Cap Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install rear bearing cap and tighten bolts as follows.

Tighten bolts 1, 3, 7 to 10 Nm.
Tighten bolts 2, 4, 5, 6, 8, 9 in stages in a diagonal sequence

Fasten drive sprocket for power take-off hand-tight.
Install power take-off drive chain → Power take-off drive chain, removing and installing .
Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

The rest of installation is in reverse order of removal, note the following:

Install lower timing chain cover → Lower timing chain cover, removing and installing .
Install crankshaft seal, timing chain side → Crankshaft seal (timing chain side), replacing .
Install oil filter housing → Oil filter housing, removing and installing .
Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .

Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
Install dual-mass flywheel → Dual-mass flywheel, removing and installing .
Install clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.
Install engine → Engine, installing .

Torque specifications

Component		Nm
Front bearing cap to cylinder block		22
Bearing cap	Front bearing cap	9
at rear on	Cylinder block	22
Drive sprocket for power take-off to shaft		64