Servicing intermediate housing — AUDI
Servicing intermediate housing on Audi: factory workshop procedure. Full factory text, tools and checks.
Workshop procedure for AUDI — the factory write-up, straight from real workshop data.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
Servicing intermediate housing
Special tools and workshop equipment required
Press tool
VW 408 A
Guide pin
10-15
Installing tool
30-504
1
Internal puller
Kukko 21/2
4
Counter-support
Kukko 22/1
Depth gauge
Exploded view
Intermediate housing
If renewing, re-determine shim
“S4”
Chapter
Outer race for small tapered roller bearing for pinion shaft
Driving out
Fig.
Pressing in
Fig.
If renewing, re-determine shim
“S4”
Chapter
Shim
“S4”
Table of adjustments
Anchor
Re-determining
Chapter
Roller bearing for input shaft
Pressing out and pressing in
Fig.
Measuring installation depth
Fig.
Ball sleeves
4x
For selector rods or for follower for reverse gear
Driving out and driving in ball sleeves for selector rods
Fig.
Pulling ball sleeve out of follower for reverse gear
Fig.
Driving ball sleeve into follower for reverse gear
Fig.
Bolt, 35 Nm
For relay lever
Pin 7x28
Drive in and drive out with drift
Selector gear for reverse gear
Synchro-ring for reverse gear
With locking pins
Checking for wear
Fig.
Installation position: flat on circumference of synchro-ring faces towards input shaft
Anchor
Spring
Installation position: hook single angled end into recess on synchro-ring. Turn double angled end anti-clockwise and insert into opening on intermediate housing.
Shaft for reverse selector gear
Retaining plate
Installation position: chamfers of holes for locking pins of synchro-ring face towards intermediate housing
Anchor
Spring clip
Bolt, 25 Nm
Self-locking
Renew
Relay lever for reverse gear
Follower for reverse gear
Pulling out ball sleeve
Fig.
Driving in ball sleeve
Fig.
Selector rod for 5th and 6th gear
Renew only complete with follower
Item
Removing and installing ball sleeves for selector rods
Install ball sleeve with the inscribed side (thicker metal) facing the drift.
Dimension
a
= 2.5 mm.
Checking synchro-ring for wear
Press synchro-ring onto tapered seats of the gear wheel.
Check gap
a
with a feeler gauge.
Dimension, new: 0.75 ... 2.3 mm.
Wear limit 0.2 mm.
Pulling ball sleeve out of follower for reverse gear
A
Counter-support
Kukko 22/1
B
Internal puller 14.5 ... 18.5 mm
Kukko 21/2
Driving ball sleeve flush into follower for reverse gear
Install ball sleeve with the inscribed side (thicker metal) facing the drift.
Pressing out and pressing in roller bearing for input shaft
Measuring installation depth
Fig.
Measuring installation depth of roller bearing for input shaft
Installation depth
a
= 7 mm.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.