Installing cover for gearbox housing and 5th/6th gear — AUDI

🧭 Before you start

Fits: VW Caddy IV (SA, 2015–2020)

• Special tools named: feeler gauge

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• Wear protective gloves! — Heat gear wheel for 5th gear to about 100 °C with inductive heaterVAS 6414 before installing.
• If synchro-hub and locking collar for 5th/6th gear are dismantled, assemble them before installing and .
• When driving on, ensure that synchro-ring moves freely.
• Drive on gear wheel for 6th gear. Make sure that teeth of gear wheel for 6th gear and those of synchromeshed gear for 6th gear mesh properly.
• Engage 2 gears (arrow 1) to (arrow 3) before tightening securing bolts (A).

📋 Procedure

1. Lock bolt of support bridge30 - 211A with nut (A).
2. ⚠ Wear protective gloves! — Heat gear wheel for 5th gear to about 100 °C with inductive heaterVAS 6414 before installing.
3. Drive on gear wheel for 5th gear.
4. Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchromeshed gears. Measure gap (a) with a feeler gauge:
5. Fit synchromeshed gear for 5th gear with needle bearing.

6. Fit 5th gear synchro-ring on synchromeshed gear.
7. If synchro-hub and locking collar for 5th/6th gear are dismantled, assemble them before installing and .
8. Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.
9. ⚠ Wear protective gloves! — Heat synchro-hub for 5th gear to about 100°C using inductive heaterVAS 6414 before installing. [Note: When driving on, ensure that synchro-ring moves freely.]
10. ⚠ Wear protective gloves! — Heat inner race of cylindrical roller bearing for 6th gear synchromeshed gear to max. 100°C, and drive onto input shaft.
11. Fit synchro-ring for 6th gear.
12. Fit synchromeshed gear for 6th gear with needle bearing.
13. Heat inner race of cylindrical roller bearing to max. 100°C, and drive onto input shaft.
14. ⚠ Wear protective gloves! — Fit sleeve (A) onto gear wheel for 5th gear.
15. ⚠ Wear protective gloves! — Heat gear wheel for 6th gear to max. 100°C, and press it on.
16. Move locking collar for 5th/6th gear to neutral position. The synchromeshed gear for 6th gear can then turn while gear wheel for 6th gear is being driven on.
17. Drive on gear wheel for 6th gear. Make sure that teeth of gear wheel for 6th gear and those of synchromeshed gear for 6th gear mesh properly.
18. ⚠ Wear protective gloves! — Heat inner race of cylindrical roller bearing (A) to max. 100°C, and drive it onto output shaft.
19. Now loosen support for input shaft.
20. ⚠ Wear protective gloves! — Tighten securing bolts for synchro-hub and gear wheel for 5th/6th gear .
21. Engage 2 gears (arrow 1) to (arrow 3) before tightening securing bolts (A).
22. Input shaft and output shaft are locked when both gears are engaged. Now both bolts can be tightened.
23. Install 5th/6th gear selector fork.
24. Engage 5th gear.
25. Loosen bolt (1).
26. Press down selector jaw and locking collar (arrows), and tighten bolt (1) to specified torque.
27. If necessary, repeat adjustment.
28. Engage 5th gear and then 6th gear.
29. Disengage gear.
30. Shift through all gears.
31. Apply sealing paste evenly to sealing surface of gearbox housing cover.
32. Install gearbox housing cover .
33. Fit release bearing guide sleeve .
34. Fit clutch release lever and release bearing .
35. Fill with gear oil .

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