Removing and installing bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, pinion shaft and hollow shaft — AUDI

🧭 Before you start

Fits: Audi A4 Cabriolet B6/B7 (8H), Audi A4 B6/B7 (8E)

• Opens: engine oil, gearbox oil
• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• When pulling off, the bearing housing is pressed slightly off the end cover by the spring (A).
• The internal puller3275 engages in a circular groove in the inner race when pulling off (arrow).
• Always use hexagon bolt (length 50 mm) for clamping sleeve3116.
• Do not damage synchro-ring for 6th gear when pressing out roll pin.Do not drive out roll pin, otherwise selector rod bearing will be damaged.
• Mark locking collar for 5th and 6th gear (arrow 1) and synchronising hub (A) (paired) in installation position (arrow 3).

🔩 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. Secure gearbox to engine/gearbox supportVW 540.
2. Place used oil collection and extraction unitV.A.G 1782 below gearbox.
3. Drain gear oil (2 oil drain plugs).
4. Slacken off bolt (1) and remove leaf spring (2).
5. Remove clutch release lever (4) together with release bearing (3) and intermediate piece (5).

6. Unbolt guide sleeve.
7. Unbolt bearing housing (arrow) and pull off. [Note: When pulling off, the bearing housing is pressed slightly off the end cover by the spring (A).]
8. When removing the bearing housing, note position of dished spring (C).
9. Remove shims (B), note thickness and re-determine if necessary .
10. Pull Torsen differential out of end cover.
11. Pull oil collector out of end cover (arrow) until it is free to move.
12. Swing oil collector (arrow) down and guide out through hole in end cover.
13. Remove oil collector.
14. Remove locking bolts (A) for selector shaft from gearbox housing.
15. Remove 3 bolts (B) for selector shaft cover and remove cover.
16. Pull out selector shaft.
17. Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear); do this by moving two gear selector plates (arrows).
18. Unscrew multi-point socket head bolt (arrow B) in input shaft through hole (arrow A) in end cover.
19. Remove the two securing bolts (arrows C) for end cover at needle bearing support plate (arrow D).
20. Remove support plate.
21. Remove and clean the 2 magnets (arrows A).
22. Unscrew the 5 bolts (arrows B) securing end cover.
23. Pull off 2nd inner race for input shaft ball bearing from input shaft. [Note: The internal puller3275 engages in a circular groove in the inner race when pulling off (arrow).]
24. Remove end cover with end cover/intermediate housing gasket.
25. Pull dowel sleeves out of intermediate housing.
26. Pull off 5th speed selector gear and spring together with 1st inner race (A) for input shaft ball bearing.
27. Take out synchro-ring for 5th gear.
28. Take out circlip for 5th gear wheel.
29. Lock hollow shaft in position by engaging two gears .
30. Pull off 5th gear wheel. [Note: Always use hexagon bolt (length 50 mm) for clamping sleeve3116.]
31. Remove shim (B) for 5th speed gear, note thickness and re-determine if necessary .
32. Remove spacer sleeve (A).
33. Press out roll pin (A) for selector fork for 5th and 6th gear. [Note: Do not damage synchro-ring for 6th gear when pressing out roll pin.Do not drive out roll pin, otherwise selector rod bearing will be damaged.]
34. Take hold of follower and pull selector rod together with selector fork for 5th and 6th gear and locking collar as far as possible away from intermediate housing (until stop is felt).
35. Mark locking collar for 5th and 6th gear (arrow 1) and synchronising hub (A) (paired) in installation position (arrow 3).
36. Detach follower together with selector fork and locking collar from selector rod.
37. Pull off 6th speed selector gear, synchro-ring for 6th gear, synchronising hub for 5th and 6th gears and needle bearing inner race for 5th speed selector gear.
38. Remove selector rod locking bolts.
39. Drive out dowel sleeves from intermediate housing and unbolt intermediate housing from gearbox housing.
40. Secure pinion shaft relative to hollow shaft e.g. with hose clip, to prevent it falling out.
41. Separate intermediate housing with input shaft, pinion shaft, hollow shaft and internal selector mechanism (as a single unit) from gearbox housing.
42. Remove circlip from selector rod for 1st and 2nd gear and take off follower (A).
43. Pull out selector rod (B) for 5th and 6th gear.
44. Remove follower (C) for reverse gear.
45. Pull thrust washer (arrow A) for needle bearing for 6th gear off shaft.
46. Use right-angled circlip pliers to remove circlip (arrow B) for inner race for roller bearing.
47. Remove inner race for roller bearing (arrow C) (not a press fit).
48. Take input shaft (A) with selector rod and selector fork for 3rd and 4th gear out at an angle from intermediate housing.
49. Unscrew hexagon bolt (D) and take off spring clip (B) and retaining plate (A). Then pull out shaft (C) for reverse gear wheel.
50. Take out spring, synchro-ring and reverse gear wheel.
51. Remove relay lever for reverse gear. [Note: Pinion shaft and hollow shaft can be removed complete if the 6th speed gear can be easily levered off.If it is necessary to press off the 6th speed gear, the pinion shaft must be pulled out of the hollow shaft.]
52. Remove the securing element fitted previously in order to prevent the pinion shaft from falling out.
53. Pull pinion shaft out of hollow shaft (arrow D), when doing this catch the tapered rollers (arrow A) (Qty. 23).
54. Remove corrugated spring (arrow B) and needle roller bearing (arrow C). [Note: Carefully protect bearings from dirt, clean if necessary.]
55. Check bearings for completeness:
56. Press off 6th gear wheel. [Note: Because of the type of fit, it may be possible to press gear off easily.]
57. Remove hollow shaft (or pinion shaft and hollow shaft) from intermediate housing together with selector rod and selector fork for 1st and 2nd gear.
58. Insert hollow shaft into intermediate housing together with selector fork and selector rod for 1st and 2nd gears (without follower).
59. ⚠ Wear protective gloves. — Heat 6th gear wheel to approx. 100 °C, fit and press onto stop so it is free of play.
60. Insert tapered roller bearing for pinion shaft/hollow shaft with greaseG 052 128 A1.

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