Removing and installing 5th gear — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

• Opens: gearbox oil
• Special tools named: puller, feeler gauge
• Renewed: synchro-ring

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• Due to changes in the gearbox housing during production, there are various procedures for removing the synchromeshed gear for fifth gear.
• Spring (3) and locking collar (4) do not need to be removed.
• If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.
• First set half sleeve T10309/1 between 5th gear wheel (A) and support for selector fork for 5th gear (B). (If necessary, half sleeve must be pressed to end position.)
• When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.

📋 Procedure

1. Bolt gearbox to repair stand.
2. Set drip tray for workshop hoistVAS 6208 underneath.
3. Drain gear oil.
4. Remove clutch release lever, release bearing and guide sleeve .
5. Unbolt gearbox housing cover (arrow). [Note: Due to changes in the gearbox housing during production, there are various procedures for removing the synchromeshed gear for fifth gear.]

6. Check whether puller hooks T10040/2A can be inserted correctly under 5th gear wheel. [Note: When the puller hooks T10040/2A can be inserted correctly, the 5th gear can be removed separately .When the puller hooks T10040/2A could not be inserted correctly because the puller hooks prematurely contact the wall of the gearbox housing (A) or ribs in gearbox housing beneath gear wheel (B), remove 5th gear synchro-hub, 5th gear wheel and gearbox housing together .]
7. Cover openings with a cloth.
8. Move selector fork (1) to neutral position.
9. Remove bolt (2) with selector fork for 5th gear.
10. Remove both bolts (2) for pivot pins
11. Pull out pivot pin.
12. Remove selector fork.
13. Spring (3) and locking collar (4) do not need to be removed.
14. Remove bolts (A) for synchro-hub and 5th gear wheel. To do so, engage 5th gear (arrow 1) and 1st gear (arrow 2) and (arrow 3).
15. Input shaft and output shaft are locked when both gears are engaged. Synchro-hub and gear wheel cannot turn. Both bolts can now be loosened. [Note: If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.] [Note: Use puller T10309.]
16. First set half sleeve T10309/1 between 5th gear wheel (A) and support for selector fork for 5th gear (B). (If necessary, half sleeve must be pressed to end position.)
17. Turn half sleeve T10309/1 to opposite side (direction of arrow).
18. Introduce thread insert T10309/3 into shell half.
19. Now, fit second half sleeve T10309/1, and place tube T10309/2 on assembly.
20. After pulling off synchro-hub, check for damage.
21. Renew synchro-ring.
22. Remove 5th gear synchromeshed gear with needle bearing.
23. Pull off gear wheel for 5th gear. (Shown here on another gearbox.)
24. First, install puller hook (A). [Note: When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.]
25. Heat gear wheel beforehand with hot air blowerV.A.G 1416 if necessary.
26. Lock bolt of support bridge30-211A with nut (A).
27. Heat gear wheel for 5th gear to maximum 120° C.
28. ⚠ Wear protective gloves! — Drive on gear wheel for 5th gear.
29. Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap (a) with a feeler gauge.
30. Install 5th gear synchromeshed gear with needle bearing.
31. Place 5th gear synchro-ring on synchromeshed gear.
32. If synchro-hub and locking collar for 5th gear are dismantled, assemble before installing .
33. Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.
34. Drive on 5th gear synchro-hub. [Note: When driving on, ensure that synchro-ring moves freely.]
35. Screw in securing bolts for synchro-hub and gear wheel for 5th gear.
36. Screw in bolts (A) for synchro-hub and 5th gear wheel. To do this, engage 5th gear (arrow 1) and 1st gear (arrow 2) and (arrow 3).
37. Input shaft and output shaft are locked when both gears are engaged. Synchro-hub and gear wheel cannot turn. Now both bolts can be tightened to specified torque.
38. Install 5th gear selector fork.
39. Engage 5th gear. Loosen bolt (1).
40. Press locking collar (2) and selector jaw (3) in direction of arrow. Then, tighten bolt (1).
41. Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.
42. Shift through all gears.
43. Apply sealantElectronic Parts Catalogue evenly to sealing surface of gearbox housing cover.
44. Install gearbox housing cover .
45. Install left and right flange shaft with springs, thrust washers and tapered rings.
46. Install release bearing guide sleeve .
47. Install clutch release lever and release bearing .
48. Fill with gear oil .

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