Exploded view - servicing gearbox housing and clutch housing — AUDI

Audi
Audi A3
2004
Audi A3 Cabriolet
2008
Power transmission
5-speed manual gearbox 0A4
Edition
02.2011
Exploded view - servicing gearbox housing and clutch housing
Special tools and workshop equipment required
Drift
VW 295
Adapter
VW 295 A
Thrust plate
VW 447 H
Thrust pad
VW 512
Press tool
VW 454
Tube
2040
Puller
VW 228 B
(not used on this gearbox)
Drift
VW 222 A
(not used on this gearbox)
Assembly device
3066
(assembly device spindle)
Thrust piece
3124
(for two-piece oil seal and sleeve)
Multi-purpose tool
VW 771
(for one-piece oil seal and sleeve)
Puller hook
VW 771/37
(for one-piece oil seal and sleeve)
Thrust piece
T10148
(for one-piece oil seal and sleeve)
Gearbox housing
If renewed: Adjust input shaft and differential
Chapter
Needle bearing
For output shaft
Removing
Fig.
Installing and securing
Fig.
Oil filler plug
35 Nm
Gear oil level cannot be checked by removing oil filler plug
If gearbox was dismantled, fill with gear oil before installing
Capacity of manual gearbox (gearbox completely dismantled)
1.9 ltr.
Capacity of manual gearbox (gearbox partially dismantled)
Chapter
1.7 ltr.
Tapered roller bearing outer race
For output shaft
Removing and installing
Chapter
If renewed: Adjust output shaft
Chapter
Shim
For output shaft
Table of adjustments
Chapter
Shim
For input shaft
Table of adjustments
Chapter
Tapered roller bearing outer race
For input shaft
Removing and installing
Chapter
If renewed: Adjust input shaft
Chapter
Tapered roller bearing outer race
For input shaft
Removing and installing
Chapter
If renewed: Adjust input shaft
Chapter
Needle bearing
Removing and installing
Chapter
Dowel sleeve
2x
Clutch housing
If renewed: ⇒ table of adjustments
Chapter
Guide sleeve
With input shaft oil seal and vulcanised O-ring
Driving out oil seal
Fig.
Driving in oil seal
Fig.
Remove guide sleeve in order to renew oil seal
Renew guide sleeve if O-ring is damaged
Socket head bolt
20 Nm
Oil seal
Renewing
Chapter
„
Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve
“
Sleeve
For oil seal
Item
Removing
Fig.
Installing
Fig.
One-piece oil seal and sleeve
If oil seal is damaged, renew both sleeve and oil seal
Removing
Fig.
Installing
Fig.
Oil drain plug
35 Nm
Without magnet
Tapered roller bearing outer race
For differential
Pressing out and pressing in
Chapter
If renewed: adjust differential
Chapter
Magnet
Held in place by joint surface of housing
Oil collector
Installing oil collector in gearbox housing
Fig.
Tapered roller bearing outer race
For differential
Pressing out and pressing in
Chapter
If renewed: adjust differential
Chapter
Shim
For differential
Table of adjustments
Chapter
Oil seal
Renewing
Chapter
„
Renewing oil seal for flange shaft (left-side)
“
Driving out needle bearing
Driving in needle bearing onto stop
Secure needle bearing in gearbox housing at three points (120° offset) with a punch.
Driving oil seal out of guide sleeve
Driving oil seal into guide sleeve (drive in onto stop)
Lever out sleeve
arrow
with screwdriver
Installing sleeve
Screw spindle
A
of
assembly device
3066
into threaded piece in differential.
Turn nut
B
and pull sleeve in onto stop with
thrust piece
3124
.
Note
If gearbox has been dismantled, press in sleeve onto stop using
thrust piece
3124
.
Pulling out sleeve and oil seal
A shoulder is located on inside diameter of sleeve.
To pull out oil seal and sleeve, apply
puller hook
VW 771/37
behind shoulder inside sleeve.
During this operation, press
puller hook
VW 771/37
firmly in against sleeve.
Installing sleeve and oil seal
Clean seat for oil seal in gearbox.
Screw spindle
A
of
assembly device
3066
into threaded piece in differential.
Turn nut
B
and pull sleeve in onto stop with
thrust piece
T10148
.
Note
If gearbox has been dismantled, press in sleeve onto stop using
thrust piece
T10148
.
Installing oil collector
A
in gearbox housing
Insert oil collector simultaneously into bore
arrow 1
and groove
arrow 2
.