Removing gearbox housing cover and 5th/6th gear: Audi A3

🧭 Before you start

Fits: Audi A3 (8V, 2012–2020)

• Renewed: synchro-ring

Don't miss

• If the shafts are not being renewed, clean remaining locking fluid out of tapped holes using a thread tap.
• 6th gear wheel and roller bearing inner race can also be pulled out using two-arm puller T10040 and claws T10040/2A.
• One corrugated spring washer is fitted below 5th gear synchro-ring and one above 6th gear synchro-ring .Check both corrugated spring washers for damage.
• Ensure that the claws do not bend outwards when pulling off the gear wheel. Check 5th gear wheel for damage after removal.

📋 Procedure

1. Remove clutch release lever and release bearing .
2. Secure gearbox on gearbox supportVW 353.
3. Unbolt gearbox housing cover (arrow).
4. Take off cover. If necessary, carefully lever up all round and alternating between sides on the protruding flanges, being careful not to damage sealing surfaces.
5. Check whether claws T10040/2A can be applied correctly below 5th gear wheel.

6. Remove 5th/6th gear selector fork as follows:
7. Cover over openings with a cloth.
8. Engage 5th gear (arrows (1) and (2)).
9. Remove 5th/6th gear selector jaw (bolt (A)).
10. Then remove both bolts (B) for pivot pins.
11. Pull out pivot pins.
12. Remove selector fork for 5th/6th gear.
13. Unscrew (bolts A) for bearing inner races on input and output shafts. To do so, engage 5th gear (arrow 1) and 1st gear (arrow 2) and (arrow 3).
14. The input and output shafts are both locked when these two gears are engaged. The two bolts can now be loosened. [Note: If the shafts are not being renewed, clean remaining locking fluid out of tapped holes using a thread tap.]
15. Pull off 6th gear wheel and roller bearing inner race for output shaft. [Note: 6th gear wheel and roller bearing inner race can also be pulled out using two-arm puller T10040 and claws T10040/2A.]
16. If necessary, heat gear wheel using hot air blowerV.A.G 1416 before pulling off.
17. First insert shell half T10309/1 between output shaft (A) and mounting for 5th/6th gear selector fork (B).
18. If necessary, press shell half into end position.
19. Turn shell half T10309/1 to opposite side in direction of (arrow).
20. Introduce thread insert T10309/3 into shell half.
21. Now fit second shell half T10309/1 and slide tube T10309/2 onto tool.
22. Please check synchro-hub for damage after removal.
23. Renew synchro-ring if necessary. [Note: One corrugated spring washer is fitted below 5th gear synchro-ring and one above 6th gear synchro-ring .Check both corrugated spring washers for damage.]
24. Now take off sleeve from 5th gear wheel.
25. Pull off 5th gear wheel.
26. First fit claws (A). [Note: Ensure that the claws do not bend outwards when pulling off the gear wheel. Check 5th gear wheel for damage after removal.]

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Running gear, front-wheel drive and four-wheel drive — Removing and installing track rods · 1 torque figures
• Detaching pulley from air conditioner compressor/re-attaching ("“Denso”" make, version "“3”") · 1 torque figures
• Detaching refrigerant lines at air conditioner compressor/attaching · 1 torque figures
• Detaching and attaching air intake box from heater and air conditioning unit · 1 torque figures
• Detaching air intake box from heater and air conditioning unit/attaching · 1 torque figures