Exploded view - removing and installing gearbox housing cover and 5th/6th gear — AUDI

Exploded view - removing and installing gearbox housing cover and 5th/6th gear
Gearbox housing
Pulling off together with 5th/6th gear
Chapter
Servicing
Chapter
5th gear wheel
Pulling off individually
Chapter
Pulling off together with gearbox housing
Chapter
Sleeve
6th gear wheel
Pulling off individually
Chapter
Pulling off together with gearbox housing
Chapter
Roller bearing inner race
For output shaft
Mark before removing
Do not interchange with roller bearing inner race for input shaft
Larger outer diameter on gearboxes manufactured from 21 08 6 onwards
Allocation
Fig.
Bolt
For output shaft
On gearboxes manufactured up to 20 08 6: tighten to 40 Nm and turn 180° further
On gearboxes manufactured from 21 08 6 onwards: tighten to 80 Nm and turn 90° further
Allocation of bolts
Fig.
Self-locking
Always renew
Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing 5th/6th gear synchro-hub and 6th gear wheel. Otherwise there is a risk that the bolts will shear off
Gearbox housing cover
With roller bearings for input and output shafts
Roller bearings for input and output shafts with larger outer diameter on gearboxes manufactured from 21 08 6 onwards
Fig.
Servicing
Chapter
Bolt
18 Nm
5x
For gearbox housing cover
Bolt
For input shaft
On gearboxes manufactured up to 20 08 6: tighten to 40 Nm and turn 180° further
On gearboxes manufactured from 21 08 6 onwards: tighten to 80 Nm and turn 90° further
Allocation of bolts
Fig.
Self-locking
Always renew
Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing 5th/6th gear synchro-hub and 6th gear wheel. Otherwise there is a risk that the bolts will shear off.
Roller bearing inner race
For input shaft
Mark before removing
Do not interchange with roller bearing inner race for output shaft
On gearboxes manufactured from 21 08 6 onwards, thrust washer and roller bearing inner race are one component
Item
Allocation of roller bearing inner race
Fig.
Thrust washer
On gearboxes manufactured up to 20 08 6
Roller bearing inner race with thrust washer
For input shaft
On gearboxes manufactured from 21 08 6 onwards
Allocation of roller bearing inner race
Fig.
Sleeve
For 6th gear needle bearing
Renew together with needle bearing
Larger diameter on gearboxes manufactured from 21 08 6 onwards
Select correct components from
Electronic parts catalogue
Needle bearing
For 6th gear
Renew together with sleeve
Larger diameter on gearboxes manufactured from 21 08 6 onwards
Select correct components from
Electronic parts catalogue
6th speed selector gear
Modified according to sleeve and needle bearing on gearboxes manufactured from 21 08 6 onwards
Select correct components from
Electronic parts catalogue
Corrugated spring washer
Gearboxes manufactured from 26 05 8 onwards
On this version, install only springs for locking pieces which do not have angled ends (as shown in
Fig.
- item 1-)
Select correct components from
Electronic parts catalogue
6th gear synchro-ring
Locking collar with synchro-hub for 5th and 6th gear
Pulling off individually
Chapter
Pulling off together with gearbox housing
Chapter
Dismantling and assembling
Fig.
and
Fig.
Locking collar modified on gearboxes manufactured from 12 06 6 onwards
Fig.
Adjusting on gearboxes manufactured up to 11 06 6
Fig.
Adjusting on gearboxes manufactured from 12 06 6 onwards
Fig.
Installing offset springs for locking pieces
Fig.
5th gear synchro-ring
Corrugated spring washer
Gearboxes manufactured from 26 05 8 onwards
On this version, install only springs for locking pieces which do not have angled ends (as shown in
Fig.
- item 1-)
Select correct components from
Electronic parts catalogue
5th speed selector gear
Needle bearing
For 5th gear
Socket head bolt
25 Nm
For pivot pin to gearbox housing
Pivot pin
5th/6th gear selector fork
5th/6th gear selector jaw
Bolt
25 Nm
Allocation of securing bolts and roller bearing inner races for input shaft
Gearbox manufacturing date
Dimension
„a“
(mm)
Dimension
„b“
(mm)
Up to 20 08 6
21
31
From 21 08 6 onwards
23.4
37
In addition: inner race and thrust washer are combined as one component
arrow
Allocation of securing bolts and roller bearing inner races for output shaft
Gearbox manufacturing date
Dimension
„a“
(mm)
Dimension
„b“
(mm)
Up to 20 08 6
21
31
From 21 08 6 onwards
23.4
37