Gear Set, Disassembling And Assembling

WARNING: This page is about a different car, the 2025 Audi A4 allroad and 2025 Audi A4 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Extracting Tool : T40413
Extracting Tool - Adapter :T40413/7
Bearing Installer - Multiple Use :32-111
Bearing Installer - Bearing Press Plate :T10084A
Press Plate :VW401
Press Plate :VW402
Press Piece - Rod :VW407
Press Piece - Multiple Use :VW412
Thrust Piece : T10205/13
Gearbox Support : T40206
Hydraulic Press :VAS 6178
Inductive Heater :VAS 6414
Seal Installer - Shaft Seal : T10431
Gearbox Assembly Tool :T40213A
Press Piece - Trailing Arm :2010
Press Piece - Multiple Use :VW426
Socket - XZN 18mm : T10162A
Valve Guide/Clutch Release Push Rod Seal Drift :10-206
Bearing Installer - Differential Bearing :40-21
Two-Arm Puller (Kukko 20/10) :VAS 251 001

Disassembling

-- Remove the gear set. Refer to GEAR SET, REMOVING AND INSTALLING .

-- Remove the oil pan.

AWD Vehicles

-- Remove the circlip -arrow-.

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-- Remove the bearing inner race -arrow- using the Two-Arm Puller (Kukko 20/10) :VAS 251 001 and Seal Installer - Shaft Seal :T10431/1 .

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Continuation for all vehicles

-- Install the bolts (M8 x 30) -2- in the threaded holes marked with -C- from the Adapter (Replacement Component) :T40413/7 -1-.

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-- Bolt the Adapter (Replacement Component) :T40413/7 with the Gearbox Assembly Tool :T40213A .

-- Tension the Gearbox Assembly Tool : T40213A in the vise or install on the Gearbox Support : T40206 .

-- Insert the gear set -1- in the Gearbox Assembly Tool : T40213A .

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Conditions

The bolts from the Adapter (Replacement Component) :T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter :T40413/7
4 - Gearbox Assembly Tool :T40213A
5 - Adapter 8 of the Extracting Tool : T40413
6 - Nut of 3 the Gearbox Assembly Tool : T40213A

-- Switch the gearshift rail/fork for gear 4/6 -1-, gearshift rail/fork for gear 5/7 -2- and gearshift rail/fork for gear 1/3 -3- in the -direction of the arrow-.

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-- Warm up the bolt of the output shaft -arrow- to approximately 100°.

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-- Remove the bolt -arrow- with Socket - XZN 18mm : T10162A -1-.

Tip

The bolt has a high loosening torque.

If the oil pipe -2- damages the output shaft when warming up the bolt, replace the oil pipe.

-- Drive out the oil pipe -2- using the Valve Guide/Clutch Release Push Rod Seal Drift :10-206 -1- from the output shaft in the -direction of the arrow-.

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-- Shift all gears into the neutral position.

-- Remove the bolt -arrow- and remove the shift forks for 4/6 gear and 5/7 gear together.

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-- Remove the input shaft 1 from the gear set.

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Tip

When removing the input shaft 1, the 7th gear wheel may be loosened and can fall.

-- Switch the gearshift rail/fork for gear 1/3 -1- and gearshift rail/fork for gear 2/reverse gear -2- upward in the -direction of the arrow-.

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-- Screw in the Thrust Piece :T10205/13 in the Hydraulic Cylinder :VAS 6178 .

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-- Remove the drive wheel for spur gear unit -1- and output shaft for roller bearing inner race -2-.

Fig 1: Drive Wheel for Spur Gear -1- and Drive Wheel Roller Bearing Inner Race -2-

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3 - Press Piece - Multiple Use :VW426
4 - Screwdriver Bit 2 of the Extracting Tool : T40413
5 - Pull 1 of the Extracting Tool : T40413
6 - Hydraulic Press :VAS 6178

-- Remove the spacer sleeve.

-- Press off the 4th gear -1-.

Fig 2: Press on the 4th Gear -1-, vehicles without Self-Locking Center Differential

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2 - Screwdriver Bit 2 of the Extracting Tool : T40413
3 - Hydraulic Press :VAS 6178
4 - Pull 1 of the Extracting Tool : T40413

-- Remove the circlip -2- for the drive axle 2 -1-.

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-- Align the drive axle 2 -1-.

Fig 3: Align the Drive Axle 2 -1-

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Conditions

The bevel -arrow- of the drive axle 2 -1- must be located on the side of the intermediate sprocket for the reverse gear -2-.

-- Press off the drive axle 2 -1-.

Fig 4: Press Out the Drive Axle 2 -1-, Vehicles without Self-Locking Center Differential

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Conditions

The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate :T10084A -arrow-.
A second technician is necessary to press out.

2 - Bearing Installer - Multiple Use :32-111
3 - Press Piece - Rod :VW407
4 - Bearing Installer - Bearing Press Plate :T10084A
5 - Press Plate :VW401
6 - Press Plate :VW402

Assembling

-- Warm up the output shaft bearing -1- using the hot air gun.

Fig 5: Insert the Input Shaft 2 -2- in the Bearing Bracket

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-- Insert the input shaft 2 -2- in the bearing bracket.

Conditions

The bevel -arrow- of the output shaft 2 must be located on the side of the intermediate sprocket for the reverse gear -3-.

-- Press input shaft 2 -2- into the bearing bracket -3- using the Press Piece - Multiple Use : VW412 and sleeve 10 of the Extracting Tool : T40413 .

Fig 6: Press in the input shaft 2 -2- in the Bearing Bracket -3-

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Conditions

Pay attention to the splines -arrows-.

-- Determine and insert the thickest circlip -2- that can still be inserted for the drive axle 2 -1-.

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Circlip thickness (mm)
2.41	2.45	2.49
2.53	2.57

-- Warm the 4th gear to 120° using the Inductive Heater : VAS 6414 .

Fig 7: 4th Gear -1-, Installing

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-- Press on the 4th gear -1- using the Bearing Installer - Differential Bearing : 40-21 .

Conditions

Pay attention to the splines -arrow- for 4th gear -1- and the 4th gear assembly -2-.

-- Position the spacer sleeve -1-.

Fig 8: Drive Wheel for Spur Gear -2-, Pressing on

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-- Warm the drive wheel for spur gear unit -2- to 120 °C (248 °F) using the Inductive Heater :VAS 6414 .

-- Press on the spur gear unit drive wheel -2- using the Bearing Installer - Differential Bearing : 40-21 .

Conditions

Installation position: The groove on the drive wheel of the spur gear unit points to the Bearing Installer - Differential Bearing :40-21 .

-- Warm the output shaft roller bearing inner race -1- using the Inductive Heater :VAS 6414 to 120 °C (248 °F).

Fig 9: Press on the Output Shaft Roller Bearing Inner Race -1-

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-- Install the output shaft roller bearing inner race -1- using the Press Piece - Trailing Arm : 2010 .

Conditions

Installation position: the lettering on the bearing (thicker wall thickness) points to the Press Piece - Trailing Arm :2010 .

-- Carefully insert drive axle 1 into the gear set -arrow-.

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Conditions

Pay attention to the correct installation of the needle bearing -A- and -B-.

-- Position the shift forks and secure with the bolt -arrow-.

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If the output shaft has been disassembled:

-- Press on the locking sleeves -1- and -2-.

Fig 10: Retaining Sleeves, Removing and Installing

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Conditions

The dimension -a- of the locking sleeves is determined by the corresponding thrust pieces 5 and 6 of the Extracting Tool : T40413 .

-- Install the locking sleeve -A- for the gearshift rail/fork for gear 1 & 3 with thrust piece 6.

Fig 11: Press in the New Retaining Sleeves -A, B, C and D-

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-- Install the locking sleeve -B- for the gearshift rail/fork for gear 2/reverse gear with thrust piece 5.

Spindle 4 of the Extracting Tool : T40413
Thrust Piece 5 of 6 of the Extracting Tool : T40413
Bracket 3 of the Extracting Tool : T40413

Continuation

-- Install the bolts (M8 x 30) -2- in the threaded holes marked with -C- from the Adapter (Replacement Component) :T40413/7 -1-.

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-- Bolt the Adapter (Replacement Component) :T40413/7 with the Gearbox Assembly Tool :T40213A .

-- Tension the Gearbox Assembly Tool : T40213A in the vise or install on the Gearbox Support : T40206 .

-- Insert the gear set -1- in the Gearbox Assembly Tool : T40213A .

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Conditions

The bolts from the Adapter (Replacement Component) :T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter :T40413/7
4 - Gearbox Assembly Tool :T40213A
5 - Adapter 8 of the Extracting Tool : T40413
6 - Nut of 3 the Gearbox Assembly Tool : T40213A

-- Switch the gearshift rail/fork for gear 4/6 -1-, gearshift rail/fork for gear 5/7 -2- and gearshift rail/fork for gear 1/3 -3- in the -direction of the arrow-.

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-- Clean the internal threads of the output shaft with a thread tap.

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-- Install the new bolt -arrow- using the Socket - XZN 18mm : T10162A -1- and tighten.

-- Shift all gears into the neutral position.

AWD Vehicles

-- Warm up the bearing inner race using the Inductive Heater : VAS 6414 .

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-- Slide on the bearing inner race with shoulder -arrow- downward all the way.

Continuation for all vehicles

-- Install the circlip -arrow-.

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-- Install the oil pan.

-- Install the gear set. Refer to GEAR SET, REMOVING AND INSTALLING .

Tightening Specifications

Refer to Overview - Bearing Bracket .
Refer to Overview - Output Shaft .