Dismantling gearbox: Audi A6 C6

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Opens: gearbox oil
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: V.A.G 1306, puller

Don't miss

• If the input shaft or gearbox housing is not to be renewed, note the thickness of the circlip.
• Check the gear teeth on the selector gears and gear wheels for damage after pulling them off.
• Counter-hold two-arm puller using e.g. open end spanner (B).If the needle bearing inner race for 6th gear is in contact with press toolVW 433, insert locking pin2064 into hole in input shaft to pull off the components all the way.
• Counter-hold puller(A) using e.g. gearbox bracket2004.
• Risk of damage to dog teeth on 4th speed selector gear.Hooks of two-arm puller must not come into contact with dog teeth of 4th speed selector gear during removal. — Counter-hold two-arm puller using e.g. open end spanner (B).

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Mount gearbox on assembly stand.
2. Place drip tray, e.g. V.A.G 1306, under gearbox.
3. Drain gear oil.
4. Remove clutch release lever (A) together with release bearing.
5. Remove guide sleeve (B)

6. Remove dished spring (C).
7. Then remove circlip (D) in front of ball bearing for input shaft. [Note: If the input shaft or gearbox housing is not to be renewed, note the thickness of the circlip.]
8. Pull the ball bearing for input shaft out of gearbox housing.
9. Remove the circlip (arrow) behind the ball bearing for input shaft. [Note: If the input shaft or gearbox housing is not to be renewed, note the thickness of the circlip.]
10. Remove bolts (arrows) and take off selector shaft cover (A).
11. Unscrew the two locking bolts (1) for selector shaft.
12. Push selector shaft (2) into gearbox as far as it will go, simultaneously removing pin (3).
13. Pull out selector shaft.
14. Move two selector rods (arrow A) and (arrow B) to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).
15. Unscrew securing bolts for gearbox cover (arrows).
16. Carefully pull off gearbox cover (A) towards rear. The bearing housing (B) remains fitted to the gearbox housing (C).
17. Secure bearing housing to gearbox housing (arrows) with two M8 bolts (length approx. 70 mm) and washers.
18. Tighten these 2 bolts (arrows) to max. 5 Nm. — 5 Nm (3.7 lb-ft)
19. Detach oil collector (A).
20. Check that the 2 gears are still engaged and then remove multi-point socket head bolt (1) for input shaft.
21. Detach 6th speed selector gear with inner race for roller bearing and thrust washer. [Note: Check the gear teeth on the selector gears and gear wheels for damage after pulling them off.]
22. ⚠ Risk of damage to dog teeth on 6th speed selector gear.Hooks of two-arm puller must not come into contact with dog teeth of 6th speed selector gear during removal. — Remove synchro-ring and needle bearing for 6th speed selector gear.
23. Pull off 6th gear wheel.
24. Remove spacer sleeve from output shaft.
25. Pull out pin with clip (A) for securing selector fork for 5th and 6th gear from selector rod (B).
26. Move selector fork (C) downwards and detach with locking collar (D).
27. Heat synchro-hub (arrow) for 5th and 6th gear to approx. 100 °C using hot air blowerV.A.G 1416.
28. Pull off 5th speed selector gear together with needle bearing inner race for 6th gear and synchro-hub for 5th/6th gear. [Note: Counter-hold two-arm puller using e.g. open end spanner (B).If the needle bearing inner race for 6th gear is in contact with press toolVW 433, insert locking pin2064 into hole in input shaft to pull off the components all the way.]
29. Pull off 4th and 5th gear wheels together. [Note: Counter-hold puller(A) using e.g. gearbox bracket2004.]
30. Pull off 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.
31. ⚠ Risk of damage to dog teeth on 4th speed selector gear.Hooks of two-arm puller must not come into contact with dog teeth of 4th speed selector gear during removal. — Counter-hold two-arm puller using e.g. open end spanner (B).
32. Remove synchro-ring and needle bearing for 4th speed selector gear.
33. If fitted, remove clamping washer (A) from selector rod for 3rd and 4th gear, using side-cutting pliers or similar.
34. Remove spring (B).
35. Pull pin with clip (A) securing selector fork for 3rd and 4th gear out from selector rod (B).
36. Detach selector fork (C) with locking collar (D).
37. Remove circlip for 3rd gear and 4th gear synchro-hub and note thickness of circlip.
38. Pull off 3rd speed selector gear with synchro-hub for 3rd and 4th gear. [Note: Counter-hold puller(A) using e.g. gearbox bracket2004 to prevent plate T40086 from making contact with 3rd gear wheel or selector rod for 5th and 6th gear.]
39. Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.
40. Pull off thrust washer (B) for 3rd speed selector gear.
41. Remove circlip for 3rd gear wheel and note thickness of circlip.
42. Pull off 3rd gear wheel.
43. Unscrew bolts (arrows) for reverse shaft support.
44. Unscrew the 2 bolts (A) for bearing housing at gearbox housing.
45. Remove the bearing housing (B) together with the shafts.
46. Insert an internal puller(A) e.g. Kukko 21/2 into bore for reverse shaft support.
47. Spread open internal puller far enough for it to make contact with reverse shaft support (B).
48. Drive reverse shaft support carefully out of bearing housing (direction of arrow) and remove with reverse gear wheel.
49. Now pull out input shaft (A) carefully from bearing housing at an angle from the front (direction of arrow).
50. Pull pin with clip (A) for securing selector fork for reverse gear out from selector rod (B).
51. Detach selector fork (C) with locking collar (D).
52. Press off synchro-hub for reverse gear from output shaft. [Note: Place the bearing housing onto thrust platesVW 401 and VW 402 so that the output shaft and selector rods are not damaged when pressing off the synchro-hub.]
53. Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchro-hub.
54. Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.

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