Assembly sequence - gearbox without circlip (A) for input shaft sealing cap — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: engine oil
• Renewed: grooved ball bearing

Don't miss

• If one of the bolt holes is not flush with the gearbox support, please insert a washer (or washers) between the bolt hole and the gearbox support.
• One of the bolts (arrow) is outside the joint flange.
• If necessary, carefully apply a lever to the protruding flanges on alternate sides of the gearbox housing, taking care not to damage the sealing surfaces.
• If required, the differential can be put back in the clutch housing after lifting the shafts.
• Always renew grooved ball bearing on input shaft .

📋 Procedure

1. Secure gearbox to assembly stand with bolts (arrows). [Note: If one of the bolt holes is not flush with the gearbox support, please insert a washer (or washers) between the bolt hole and the gearbox support.]
2. Turn gearbox on assembly stand with oil drain plug downwards.
3. Place drip tray underneath.
4. Drain off gear oil.
5. Remove slave cylinder with release bearing (arrows).

6. Put selector shaft in neutral position.
7. Remove locking bolt (2).
8. Then remove bolts (3).
9. Remove reversing light switch F4(1).
10. Pull selector shaft (4) out of gearbox housing.
11. Remove flange shaft and stub shaft.
12. Remove bolts (B) securing gearbox housing from inside clutch housing. [Note: One of the bolts (arrow) is outside the joint flange.]
13. Lock input shaft by fitting installing sleeveVW 455 over input shaft and against clutch housing.
14. Tighten splitter(A), e.g. Kukko 17/0 behind splines on input shaft.
15. Pierce rubber in centre of sealing cap (C) with a screwdriver.
16. Pull sealing cap out of gearbox housing.
17. Hold one end of circlip with screwdriver(A).
18. Lever other end of circlip out of slot in grooved ball bearing in direction of (arrow) with 2nd screwdriver(B).
19. Lever circlip out further by repositioning screwdriver(B).
20. Where fitted, detach washer (1) from gearbox housing (2).
21. Remove gearbox housing/clutch housing securing bolts (A).
22. Screw adapter VW 771/40 into threaded hole in gearbox housing.
23. Using hot air blowerV.A.G 1416, heat area around seat of input shaft ball bearing in gearbox housing for approx. 10 minutes to approx. 100°C.
24. Using multi-purpose tool VW 771/1, pull gearbox housing off clutch housing in direction of (arrow). [Note: If necessary, carefully apply a lever to the protruding flanges on alternate sides of the gearbox housing, taking care not to damage the sealing surfaces.]
25. If fitted, detach washer (1) from grooved ball bearing (2).
26. When renewing the gearbox housing, check whether the washer has to be re-installed .
27. Remove splitter(A) and installing sleeve VW 455 from input shaft.
28. Lift up differential (1) with your left hand. With your right hand, lift 1st - 4th gear output shaft together with selector rods (2)(arrow A).
29. At the same time, the second mechanic must lift the input shaft, reverse shaft and 5th/6th gear output shaft (3) out of the clutch housing together with the selector rods (arrow B). [Note: If required, the differential can be put back in the clutch housing after lifting the shafts.]
30. Drive out input shaft oil seal with sleeve30-21. [Note: Always renew grooved ball bearing on input shaft .]

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