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

🧭 Before you start

Drain the oil, remove the bevel box, slave cylinder, selector shaft and flange shafts, lock the input shaft and release the bearing circlip. Heat the housing seat and pull the housing off, then lift out the shafts and differential with a helper. Rebuild in reverse: shafts in together, support bridge fitted, bearing markings aligned, housing heated and fitted with sealing paste and new bolts. Fit the circlip, spacer if needed, selector shaft, switch, seals, slave cylinder and bevel box.

Fits: Audi A3 (8P, 2003–2012)

• Opens: engine oil
• Renewed: grooved ball bearing

Don't miss

• Always renew the input shaft grooved ball bearing.
• Heat the bearing seat for approx. 10 minutes to approx. 100°C before removing or fitting the housing.
• Mark flattened sides on bearing and housing and align the marks when fitting the housing.
• Check whether a spacer was fitted; the matching spacer must go back after the housing is installed.
• Shafts and differential come out and go in together; it needs a second mechanic.
• Do not pull the bevel box on with its bolts; it must slide fully onto the stop first.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Turn gearbox on assembly stand so that oil drain plug faces downwards.
2. Place used oil collection and extraction unitV.A.G 1782 below gearbox.
3. Drain off gear oil.
4. Unscrew bolt for flange shaft (right-side) using socket and extended bit T10107 A.
5. Remove all 4 bolts (arrows) securing bevel box to gearbox (illustration only shows 3 bolts).

6. Carefully push bevel box away from gearbox, making sure it does not fall down.
7. Remove clutch slave cylinder with release bearing (arrows).
8. Make sure that the selector shaft is not locked in position by the angled rod (arrow) when carrying out the following steps.
9. Put selector shaft in neutral position.
10. Remove locking bolt (2).
11. Remove bolts (3).
12. Remove reversing light switch F4(1).
13. Pull selector shaft (4) out of gearbox housing.
14. Remove bolt securing flange shaft (left-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever.
15. Remove bolts (B) securing gearbox housing from inside clutch housing. [Note: One of the bolts (arrow) is outside the joint flange.]
16. Lock input shaft by fitting installing sleeveVW 455 over input shaft and against clutch housing.
17. Tighten splitter(A), e.g. Kukko 17/0 behind splines on input shaft.
18. Pierce rubber in centre of sealing cap (C) with a screwdriver.
19. Pull sealing cap out of gearbox housing.
20. Hold one end of circlip with screwdriver(A).
21. Lever other end of circlip out of slot in ball bearing (arrow) with 2nd screwdriver (B).
22. Lever circlip out further by repositioning screwdriver(B).
23. Where fitted, detach spacer (1) from gearbox housing (2).
24. When renewing the gearbox housing, check whether the spacer has to be re-installed .
25. Remove bolts (A).
26. Screw adapter VW 771/40 into threaded hole in gearbox housing.
27. 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.
28. Using multi-purpose tool VW 771/1, pull gearbox housing off clutch housing (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.]
29. If fitted, detach spacer (1) from grooved ball bearing (2).
30. When renewing the gearbox housing, check whether the spacer has to be re-installed .
31. Remove splitter(A) and installing sleeve VW 455 from input shaft. [Note: A second mechanic is required for removing the shafts from the clutch housing.]
32. Lift up differential (1) with your left hand.
33. With your right hand, lift 1st - 4th gear output shaft together with selector rods (2)(arrow A).
34. 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.]
35. Remove oil seal for input shaft using oil seal extractor leverVW 681. [Note: Always renew grooved ball bearing on input shaft .]
36. Insert input shaft (1), output shaft for 5th and 6th gear (2) together with selector rod (3), selector fork (4) and reverse shaft (5).
37. Install differential (1). [Note: A second mechanic is required for installing the shafts in the clutch housing.]
38. Take 1st - 4th gear output shaft (3) with selector rods (4) in your right hand as illustrated.
39. Lift up differential slightly with your left hand.
40. At the same time the second mechanic must lift the input shaft and output shaft for 5th, 6th and reverse gear (2) slightly, together with the reverse shaft.
41. Now insert 1st - 4th gear output shaft in direction of (arrow).
42. Now, together with second mechanic, locate shafts and differential in their bearing seats.
43. Secure support bridge30 - 211 A for input shaft to clutch housing. [Note: Illustration shows clutch housing turned through 180° for clarity.]
44. Screw in bolt (A) until input shaft lifts slightly. [Note: On some gearboxes, grooved ball bearing for input shaft (A) and bearing mounting (B) are flattened on one side.Check grooved ball bearing for input shaft and gearbox housing.]
45. If necessary, fit a spacer (outside diameter = 85 mm) (1) onto grooved ball bearing (2).
46. Mark flattened sides with paint.
47. Copy markings onto top area of grooved ball bearing and top area of bearing mounting on gearbox housing (⇒ next illustration).
48. 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. [Note: Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing.]
49. Align marking (A) on grooved ball bearing with marking (B) on gearbox housing and fit gearbox housing.
50. 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. [Note: Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing.]
51. Apply sealing pasteAMV 188 200 03 evenly to sealing surface of clutch housing.
52. Fit gearbox housing and tighten new bolts (A), (B) and (C) to specified torque.
53. If a spacer was fitted on the grooved ball bearing before installing the gearbox housing, a spacer (1) (outer diameter = 78.6 mm) must also be fitted after installing the gearbox housing (2).
54. Install circlip (1) for input shaft grooved ball bearing.
55. Remove support bridge30 - 211 A for input shaft.
56. If stop sleeve for selector shaft has been removed, drive it in now (drive in until tool reaches stop).
57. Turn gearbox on assembly stand so that opening for selector shaft faces up.
58. Insert selector shaft (1) into bottom mounting (2) and into selector forks (3). [Note: The sealing cap is removed to give a better illustration.]
59. Now push selector shaft (1) against stop sleeve (2) in direction of (arrow) and run selector finger (3) down through selector forks and onto stop. [Note: If the selector mechanism cover is not parallel with the joint surface, the selector shaft is not seated in its bottom mounting.]
60. Tighten bolts (3) for selector mechanism cover (4).

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