Removing and installing input shaft ball bearing, multi-function sender, input shaft, pinion shaft, selector rods and gearbox cover — AUDI

Notes:

It is not necessary to remove the differential to remove the above-mentioned components.
Removal is only necessary when adjustments have to be carried out => adjustment overview, Page
39-39
.

Special tools, testers and auxiliary equipment required

Holding plate VW 309
Gearbox support VW 353
Pressing-in tool 3235
Drip tray V.A.G 1306
Taper roller bearing extractor V.A.G 1582
Clamping piece V.A.G 1582/2
Sealant AMV 188 001 02

Removing

Place drip tray V.A.G 1306 underneath the gearbox.
Drain gear oil.
Secure gearbox to repair stand => Page
34-61
.

Detach clutch release lever -A- with release bearing.

Notes:

Before pulling off guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.
Removing oil seal from guide sleeve => Page
30-29
.

Unscrew guide sleeve -B-.
Remove dished washer -C-.
Remove circlip -D- in front of input shaft ball bearing.
If the ball bearing, input shaft or gearbox housing is not to be replaced, note the thickness of the circlip.

Pull the input shaft ball bearing out of the gearbox housing.

Remove the circlip (arrow) behind the input shaft ball bearing.
If the ball bearing, input shaft or gearbox housing is not to be replaced, note the thickness of the circlip.

Unbolt gearbox cover -A- from gearbox housing -B-.

Remove bolts (arrows) and pull out the multi-function sender.

Remove relay shaft bolts (arrows).

Unscrew detent segment (arrow) and swivel it out.

The input shaft -A-, the pinion shaft -B-, the relay shaft -C-, the selector rods -D- with the selector shaft and the selector forks -E- should be carefully pulled out together.

Installing

Note:

If the input shaft ball bearing, the input shaft or the gearbox housing are renewed, it is necessary to re-determine the thickness of the circlips for the input shaft =>Page
35-19
, adjusting input shaft.

Swing the gearbox housing into the position shown. The components listed below can then be fitted more easily.

Put the input shaft -A-, the pinion shaft -B-, the relay shaft -C-, the selector rods -D- with the selector shaft and the selector forks -E- together.
Install these components together into the gearbox housing.

Note:

Relay shaft -C- and the selector shaft can also be fitted later =>Fig. V34-1816, Page
34-96
.

Location of gear shift mechanism in gearbox

1 -
Selector fork for 5th gear and reverse gear
2 -
Selector fork for 3rd gear and 4th gear
3 -
Selector fork for 1st gear and 2nd gear
4 -
Relay shaft
5 -
Detent mechanism
6 -
Selector shaft

Note:

Shown in illustration with input shaft and pinion shaft removed.

Turn gearbox housing and engage 3rd gear (direction of arrow).

Now install relay shaft -A-.
Insert selector shaft -B- sideways onto drilling in gearbox housing and assemble into mounting eye.
Then turn the selector shaft carefully in direction of arrow.

Then insert the detent segment and bolt it tight (arrow).

Screw in the bolts for the relay shaft (arrow).

Replace O-ring for multi-function sender.
Carefully insert multi-function sender and tighten (arrow).

Check whether the dowel sleeves for gearbox cover -A- are fitted in gearbox housing -B-.

Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
Fit gearbox cover onto gearbox housing.

Fit rear input shaft ball bearing circlip (arrow).
Slide the ball bearing onto the input shaft.
Installation position: closed side of ball cage faces towards gearbox housing

Press in ball bearing:
Slide thrust pad -A- of pressing-in tool onto input shaft.
Position pressing-in tool behind splines for clutch plate.
Screw in the bolts -B- until they make contact.
The bolts bear against the indentations in thrust piece -A-.

Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).

Now fit the front circlip -D- for the input shaft ball bearing .
Then fit dished washer -C-.
Installation position: convex side towards guide sleeve -B-

Notes:

Before fitting guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.
Installing oil seal in guide sleeve => Page
30-29
.

Fit guide sleeve -B- for release bearing.
Fit clutch release lever -A- and release bearing.