A0059185920-6-Speed Manual Gearbox 01X Front-Wheel Drive

Service
Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 01X, front-wheel drive
Edition 10.2009
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt A0059185920

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
6-speed manual gearbox 01X, front-wheel drive - Edition 10.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Servicing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Exploded view - pedal cluster (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing clutch pedal switch for engine start F194 . . . . . . . . . . . . . . . . . . 15
1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Exploded view - pedal cluster (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Exploded view - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 20
1.8 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 20
1.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.10 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Checking release bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Servicing conventional clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Removing and installing conventional clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Servicing self-adjusting clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4 Removing and installing self-adjusting clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Servicing clutch with SAC pressure plate (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.6 Removing and installing clutch with SAC pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.7 Resetting adjuster ring in SAC pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing gear knob with boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.4 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.5 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Removing gearbox on vehicles with 4-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Copying
Protected by copyright. Removing
for private orgearbox
commercial on vehicles
purposes, with
in part or 4-cylinder
in whole, is not TDI engine . . . . . . . . . . . . . . . . . . . . . . . . 74
permitted unless2.3
authorisedRemoving
by AUDI AG. AUDIgearbox
AG does on vehicles
not guarantee with any
or accept 6-cylinder
liability engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine . . . . . . . . . . . . . . . . . . 97
2.5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5 Mounting gearbox on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
6.2 Exploded view - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

6.3 Exploded view - removing and installing ball bearing for input shaft, gearbox cover, bearing
housing and selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.4 Exploded view - removing and installing 3rd to 6th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.5 Exploded view - removing and installing input shaft, output shaft, reverse gear wheel and
reverse selector gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6 Assembly sequence - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . 120
7 Servicing gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Servicing bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
9 Servicing
Protected gearbox
by copyright. Copyinghousing
for private or. commercial
. . . . . . purposes,
. . . . . .in. part
. . or
. .in. whole,
. . . .is.not
.......................... 153
10 Servicing selector shaft . . . . . . . . . . . . . . . . . . . . . .
. . . . . ......................... 159
10.1 Removing and installing selector shaft with gearbox installed . . . . . . . . . . . . . . . . . . . . . . 159
10.2 Renewing oil seal for selector shaft with gearbox removed (gearbox remains assembled)
........................................................................ 163
10.3 Renewing oil seal for selector shaft with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 165
10.4 Removing and installing reversing light switch F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Pinion shaft (output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Exploded view - pinion shaft (output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2 Dismantling and assembling pinion shaft (output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

1 Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.1 Renewing oil seal for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.2 Renewing oil seal for flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.1 Removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.1 Adjustment and marking of final drive gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.2 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.3 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.4 Recommended sequence for adjusting gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.5 Adjusting pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.6 Re-determining shim “S4” when renewing bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 221
3.7 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
ii Contents
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 01X (front-wheel drive) is fitted on
the Audi A4 2001 ▸ in conjunction with the 2.0 ltr., 2.4 ltr. and
3.0 ltr. petrol engines and the 1.9 ltr. and 2.0 ltr. TDI engines.
Location on gearbox
♦ Code letters and date of manufacture -arrow 1- or -arrow 3-
♦ Manual gearbox 01X -arrow 2-
Code letters and date of manufacture of gearbox -arrow 1-

Example: GJU 14 06 3
I I I I
I I I I
Code letters Day Month Year of manufac‐
ture (2003)
Additional data are manufacture-related.
Note
The code letters for the gearbox are also given on the vehicle data
stickers.
Manual gearbox 01X -arrow 2-
1.1 Code letters, allocation, transmission ratios, capacities

Manual gearbox 6-speed 01X (front-wheel drive)
Code letters FYAauthorised by AUDI AG. AUDIGDX
permitted unless AG does not guarantee or accept anyGJU
liability
Manufactured from 04.03 04.03 04.03
to 11.03 12.05 05.04
Allocation Model A4 2001 ▸ A4 2001 ▸ A4 2001 ▸
Engine 1.9 ltr. - 96 kW TDI 2.4 ltr. - 125 kW 3.0 ltr. - 162 kW
Ratio Final drive 32 : 9 = 3.556 31 : 8 = 3.875 30 : 8 = 3.750

i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
1. Gearbox identification 1

2nd gear 39 : 19 = 2.053 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 37 : 27 = 1.370 37 : 26 = 1.423 37 : 26 = 1.423
4th gear 32 : 31 = 1.032 33 : 31 = 1.065 33 : 31 = 1.065
5th gear 28 : 35 = 0.800 29 : 34 = 0.853 29 : 34 = 0.853
6th gear 25 : 38 = 0.658 27 : 37 = 0.730 27 : 37 = 0.730
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 litres
Specification Gear oil G 052 911 A SAE 75 W 90 (synthetic oil)
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 88 mm 88 mm 88 mm
Overall ratio iov. in top gear 2.339 2.828 2.736

Code letters GVC GVD HCF
to 06.08 11.06
Engine 3.0 ltr. - 162 kW Protected by2.0 ltr. - 147 kW 1.9 ltr. - 96 kW TDI
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI 2.0AGltr.does- 103 kW TDI
not guarantee or accept any liability
Ratio Final drive 30 : 8 = 3.750 30 : 8 = 3.750 32 : 9 = 3.556
i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 19 = 2.053 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 37 : 26 = 1.423 37 : 27 = 1.370 37 : 27 = 1.370
4th gear 33 : 31 = 1.065 32 : 31 = 1.032 32 : 31 = 1.032
5th gear 29 : 34 = 0.853 28 : 35 = 0.800 28 : 35 = 0.800
6th gear 27 : 37 = 0.730 25 : 38 = 0.658 25 : 38 = 0.658
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 litres

Code letters HCK HTA JEM
to 05.05
Engine 2.0 ltr. - 118 kW TDI 2.0 ltr. - 103 kW TDI 2.0 ltr. - 103 kW TDI
2.0 ltr. - 125 kW TDI
Ratio Final drive 30 : 8 = 3.750 32 : 9= 3.555 32 : 9= 3.555
i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2 Rep. Gr.00 - Technical data


2nd gear 39 : 19 = 2.053 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 36 : 28 = 1.286 37 : 27 = 1.370 37 : 27 = 1.370
4th gear 31 : 33 = 0.939 32 : 31 = 1.032 32 : 31 = 1.032
5th gear 26 : 37 = 0.703 28 : 35 = 0.800 28 : 35 = 0.800
6th gear 23 : 40 = 0.575 25 : 38 = 0.658 25 : 38 = 0.658
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 litres

Code letters JWR
JWS
Manufactured from in this document.
with respect to the correctness of information 03.07Copyright by AUDI AG. 05.07
to
Allocation Model A4 2001 ▸ A4 2001 ▸
Engine 2.0 ltr. - 125 kW FSI 1.9 ltr. - 85 kW TDI
Ratio Final drive 30 : 8 = 3.750 32 : 9= 3.555

i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 36 : 28 = 1.286 36 : 28 = 1.286
4th gear 31 : 33 = 0.939 31 : 33 = 0.939
5th gear 26 : 37 = 0.703 26 : 37 = 0.703
6th gear 23 : 40 = 0.575 23 : 40 = 0.575
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 litres
Clutch plate ∅ 240 mm 240 mm
Drive shaft flange ∅ 88 mm 88 mm
Overall ratio iov. in top gear 2.156 2.044
1. Gearbox identification 3
2 Transmission layout
Identification and ratio
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
❑ General layout of gear‐
box ⇒ page 113
4 - Input shaft (main shaft)
5 - Differential
6 - Pinion shaft (output shaft)
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

3 Calculating ratio “i”

Transmission ratio
Transmission ratio = No. of teeth on driv‐ : No. of teeth on
en gear drive gear
Ratios Formula
iG = Gear ratio ZG2 : ZG1
iA = Axle ratio ZA2 : ZA1
iov = Overall ratio iG x iA
Example:
6th gear Final drive
Drive gear ZG1 = 38 ZA1 = 8
Driven gear ZG2 = 25 ZA2 = 30
Calculations:
iG = 25 : 38 = 0.658
iA = 30 :by8copyright.
Protected = 3.750 Copying for private or commercial purposes, in part or in whole, is not
iov = with0.658
respectxto3.750 = 2.467
the correctness of information in this document. Copyright by AUDI AG.
3. Calculating ratio “i” 5

4 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here under the designation
“Components” ⇒ “4.2 Components”, page 6 . They apply to the
work described in this Manual.
4.1 Special tools

For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools .
4.2 Components
Gearbox
♦ Allocate bolts and other components according to gearbox
code letters; refer to ⇒ Electronic parts catalogue
⇒ “1.1 Code letters, allocation, transmission ratios, capaci‐
ties”, page 1 .
♦ After installing a replacement gearbox, check oil level and fill
up with gear oil as required ⇒bypage
Protected 110
copyright. . for private or commercial purposes, in part or in whole, is not
Copying
♦ Capacities and specifications
⇒ “1.1 Code letters, allocation, transmission ratios, capaci‐
ties”, page 1
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing gearbox ensure dowel sleeves are correctly
seated.
Sealants
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealing paste.
♦ Apply sealing paste -AMV 188 001 02- evenly and not too
thickly.
♦ Breather holes must remain free of sealing paste.

O-rings, oil seals and gaskets

♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and oil seals, always inspect the con‐
tact surface on the housing or shaft for burrs resulting from
removal or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease -G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing gaskets and oil seals, check and, if necessary,
top up oil level in gearbox ⇒ page 110 .
Locking elements
♦ Do not over-stretch circlips.
♦ Installation position for some circlips: the circlip is fitted so that
the narrow part of the gap is at the top. This also gives the
pliers a better grip when removing and installing.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
4. General repair instructions 7

Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Renew self-locking nuts and bolts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then apply locking fluid -
AMV 185 101 A1- to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a thread tap or sim‐
ilar). Otherwise there is a danger of the bolts shearing off the
next time they are removed.
Bearings
♦ Lubricate all bearings in gearbox housing with gear oil before
installing.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Do not interchange
permitted thebyouter
unless authorised AUDI AG.or AUDI
inner AGraces
does notof bearings
guarantee of the
or accept any liability
same with
size (the bearings are paired).
respect to the correctness of information in this document. Copyright by AUDI AG.
♦ If required, renew the tapered roller bearings on one shaft to‐

gether and use new bearings from a single manufacturer.
♦ Install needle bearings, ball sleeves and roller bearings so the
lettering (side with thicker metal) faces towards the installing
tool.
♦ Mark the needle bearings of the selector gears when remov‐
ing. This ensures the same installation position when re-in‐
stalling.
♦ Grease needle bearing for gearbox input shaft in rear of fly‐
wheel.

Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Do not install shims which are damaged or not in perfect con‐
dition.
Gears, synchronising hubs, inner rings for selector gears
♦ Before installing, heat inner rings for selector gears to approx.
100° C using inductive heater -VAS 6414- .
♦ Use inductive heater -VAS 6414- to heat gear wheels and
synchronising hubs to approx. 100°C before installing. Press
home onto stop when installing so there is no axial clearance.
♦ Note correct installation position.
Selector gears
♦ After installing, check 1st to 6th speed selector gears for min‐
imal axial play and freedom of movement.
Input shaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Check the input shaft for scoring around the bearing in the
crankshaft/flywheel -arrow-. Renew the needle bearing in the
crankshaft if necessary ⇒ Rep. Gr. 13 .
Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same selector gear.
♦ Check for wear; renew if necessary.
♦ Lubricate with gear oil when installing.
Checking synchro-rings with molybdenum coating

♦ Clean synchro-ring; the friction surface must be free of oil.
♦ The friction surface of an intact molybdenum coated synchro-
ring has a graphite-grey, slightly porous appearance.
♦ The synchro-ring must be renewed if very shiny areas -A- have
formed on the friction surface or if the brass-coloured metal
underneath is already visible.

Checking synchro-rings for 1st and 2nd gear

Check the coated contact surfaces -arrows 2- on intermediate ring
-B- for damage (flattened sections or particles of carbon coating
broken away).
Check inner contact surface -arrow 1- on synchro-ring -A- and
outer contact surface -arrow 4- on inner ring -C- for grooves or
scoring.
Check for damage to coating on inner rings -C- with coated con‐
tact surface -arrow 3- (particles of carbon coating broken away).
Abnormal wear on selector gears and locking collars

♦ Abnormal wear on synchro-ring or selector gear:
A - Worn chamfer on dog teeth of synchro-ring or selector gear
♦ In comparison: intact synchro-ring or selector gear:

B - Intact chamfer on dog teeth of synchro-ring or selector gear
♦ Abnormal wear on locking collar:

C - Worn chamfer on internal splines of locking collar

♦ In comparison: intact locking collar:

D - Intact chamfer on internal splines of locking collar
♦ Always renew synchro-rings with carbon coating together with
locking collar. Renew selector gears also if there are traces of
wear.
Clutch actuation, clutch
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the slave cyl‐
inder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the slave cylinder. As a result the
slave cylinder will be destroyed.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures ⇒ page 20 ).
♦ The clutch system should be bled at the same intervals as the
brake system ⇒ Maintenance ; Booklet 45 .
♦ Note assembly instructions for SAC pressure plate
⇒ page 51 .
♦ On vehicles with SAC pressure plate an adjuster ring has to
be reset when only the clutch plate is renewed ⇒ page 52 .
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦ Only blow out dual-mass flywheel with compressed air.

30 – Clutch
1 Servicing clutch mechanism
Caution
Follow steps required when disconnecting battery ⇒ Rep. Gr.

27 .
Note
♦ Lubricate all bearings and contact surfaces with polycarbamide grease -G 052 142 A2- .
♦ Before working on pedal cluster, remove storage compartment on driver's side ⇒ Rep. Gr. 68 .
♦ Make sure that no brake fluid escapes into the footwell, the plenum chamber or onto the gearbox below. If
this does happen, clean the affected area thoroughly.
♦ When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
I - Pedal cluster (LHD vehicles)

♦ ⇒ “1.1 Exploded view - ped‐
al cluster (LHD vehicles)”,
page 13
♦ ⇒ “1.2 Removing and instal‐
ling clutch pedal switch F36
”, page 14
ling clutch pedal switch for
engine start F194 ”,
page 15
ling over-centre spring”,
page 16
II - Pedal cluster (RHD vehi‐
cles)
♦ ⇒ “1.5 Exploded view - ped‐
al cluster (RHD vehicles)”,
page 17
III - Clutch hydraulics
♦ ⇒ “1.6 Exploded view - hy‐
draulic system”, page 18
♦ ⇒ “1.7 Notes on removing
and installing clutch master
cylinder and slave cylin‐permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
der”, page 20 with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ ⇒ “1.8 Function check for

clutch master cylinder and
slave cylinder”, page 20
ling clutch master cylinder”,
page 21
12 Rep. Gr.30 - Clutch

♦ ⇒ “1.10 Bleeding clutch

system”, page 28
1.1 Exploded view - pedal cluster (LHD vehicles)
1 - Mounting bracket
❑ Removing and installing
⇒ page 21
2 - Pivot pin for clutch and
brake pedal
3 - Retaining clip
4 - Hexagon socket head bolt,
25 Nm
5 - Brake pedal
❑ Maintenance-free bear‐
ing, do not grease
6 - Clutch pedal switch -F 36-
❑ May only be installed
once; must always be
renewed if removed
⇒ page 14
5 Nm
❑ Secures clutch and
brake pedal pivot pin
8 - Clutch pedal
⇒ page 21
9 - Retaining clip
10 - Retaining clip
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Item 9 (page 18)
20 Nm
12 - Clutch master cylinder
❑ Removing and installing ⇒ page 21
❑ Seal -arrow- must not be removed
13 - Over-centre spring
❑ Black side points towards clutch pedal
❑ For correct version, refer to ⇒ Electronic parts catalogue
14 - Clutch pedal switch for engine start -F194-
❑ Only on USA models
❑ Engine can only be started when clutch is fully depressed ( clutch pedal switch for engine start activated ).
❑ May only be installed once; must always be renewed if removed
15 - Torx bolt, 25 Nm
❑ For securing brake master cylinder/brake servo to mounting bracket
1. Servicing clutch mechanism 13

1.2 Removing and installing clutch pedal

switch -F36-
Note
Clutch pedal switch may only be fitted once so as to ensure a firm

fit.
Removing
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Detach electrical connector -1- on clutch pedal switch .
• The clutch pedal -3- is in the normal position (i.e. not pressed
down). The plunger -arrow- of the clutch pedal switch should
then rest against the clutch pedal.
– Release clutch pedal switch -2- by turning 45° anti-clockwise
and take out of guide.
Installing
Installation is carried out in reverse sequence; note the following:

– Pull out plunger -arrow- all the way before installing clutch
pedal switch .
• The clutch pedal should be in the normal position (i.e. not

pressed down).
– Guide clutch pedal switch -F36- through mounting hole, press
plunger against clutch pedal and secure switch by turning 45°
clockwise.
– Plug in connector for clutch pedal switch -F36- .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .

1.3 Removing and installing clutch pedal

switch for engine start -F194-
Note
To ensure a secure fit, the clutch pedal switch for engine start -
F194- must not be installed more than once.
Removing
68 .
– Detach electrical connector -3- on clutch pedal switch for en‐
gine start -F194- .
– Press clutch pedal -1- all the way down and hold it in this po‐
sition.
– At the same time, release clutch pedal switch for engine start
-F194- -2- by turning it 45° in the direction indicated -arrow-
and pull it out of the guide.
Installing
– Pull out plunger -arrow- all the way before installing clutch
pedal switch .

– When installing clutch pedal switch for engine start -F194- ,

press clutch pedal -1- all the way down -arrow A-. Hold clutch
pedal in this position.
– Guide clutch pedal switch for engine start -F194- -2- through
opening in retainer, and at the same time push plunger against
clutch pedal and secure switch by turning it 45° in the direction
indicated -arrow B-.
– Attach electrical connector -3- on clutch pedal switch for en‐
gine start -F194- .
1.4 Removing and installing over-centre

spring
Special tools and workshop equipment required
♦ Assembly clip -T40025-
Removing
68 .
– Compress over-centre spring with clutch pedal, at the same
time pressing on assembly clip -T40025- .
– Move clutch pedal to rest position and take out over-centre
spring together with assembly clip -T40025- downwards.

Installing
– Pull clutch pedal into the passenger compartment.
• Installation position of over-centre spring: black side of over-
centre spring faces clutch pedal.
– Install over-centre spring with assembly clip -T40025- , oper‐
ate clutch pedal and remove assembly clip .
1.5 Exploded view - pedal cluster (RHD vehicles)

⇒ page 21
2 - Washer
3 - Brake pedal
❑ Maintenance-free bear‐
ing, do not grease
5 Nm
❑ For securing the bearing
sleeve
25 Nm
6 - Clutch pedal switch -F 36-
❑ May only be installed
once; must always be
renewed if removed
⇒ page 14
7 - Bearing sleeve
❑ Check for freedom of
movement in clutch
pedal
8 - Clutch pedal
⇒ page 21
9 - Retaining clip
20 Nm
❑ Seal -arrow- must not be removed
12 - Over-centre spring

13 - Bolt, 22 Nm
❑ Self-locking
❑ Renew
14 - Lever
❑ Pin only fits in one position
15 - Washer
16 - Mounting
❑ For over-centre spring
17 - Torx bolt, 25 Nm
❑ For securing brake master cylinder/brake servo to mounting bracket
18 - Bolt, 25 Nm
1.6 Exploded view - hydraulic system

1 - Brake fluid reservoir

2 - Supply hose
❑ For clutch master cylin‐
der
3 - Pipe/hose assembly
❑ For plug-in connections
on master cylinder and
slave cylinder
❑ Disconnecting from
master cylinder and in‐
stalling ⇒ page 24
❑ Disconnecting from
slave cylinder
⇒ page 20
❑ Allocation for LHD and
RHD vehicles ⇒ Elec‐
tronic parts catalogue
4 - Grommet
6 - Clutch pedal
⇒ page 21
❑ Do not remove clip
-arrow A- or seal
-arrow B-.
❑ To remove pipe/hose
assembly, pull out clip
-arrow A-, but only as far
as limit stop
⇒ page 24 .
20 Nm
9 - Retaining clip
❑ Only renew when master cylinder has been removed
❑ Lever off to remove ⇒ page 19
❑ Push in to install ⇒ page 19

10 - Gearbox
11 - Clutch slave cylinder
❑ Do not operate clutch pedal after slave cylinder has been removed
❑ After working on hydraulic clutch system, bleed slave cylinder ⇒ page 28
❑ Disconnecting pipe/hose assembly ⇒ page 20
❑ Do not allow brake fluid to come into contact with gearbox.
12 - Bleeder valve
❑ Tighten to 4.5 Nm
❑ Follow correct procedure when bleeding ⇒ page 28
❑ If bleederProtected
valve has broken
by copyright. off,forit private
Copying can be removed
or commercial with in3part
purposes, mm or inAllen
whole, key
is not
13 - Dust cap with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - Clip
❑ To remove pipe, pull out clip as far as limit stop ⇒ page 20
15 - Bracket
❑ For pipe/hose assembly
❑ Attached to gearbox together with slave cylinder
16 - Hexagon socket head bolt, 25 Nm
❑ Slave cylinder to gearbox
❑ Self-locking
❑ Renew
17 - Retaining clip
18 - Gasket
19 - Securing bolt
❑ For brake fluid reservoir
Levering retaining clip -A- off in direction of arrow
Pressing operating rod for master cylinder into retaining clip -A-
(press in direction of -arrow-).

Disconnecting slave cylinder from pipe/hose assembly

Removing
– To remove pipe/hose assembly, use a screwdriver to lever off
clip -A- as far as the stop. Only then can the pipe/hose as‐
sembly be pulled out.
Installing
– Press retaining clip -A- in as far as it will go.
– Insert pipe/hose assembly -B- in slave cylinder so that it en‐
gages audibly.
– Pull on pipe/hose assembly to check it is secure.
1.7 Notes on removing and installing clutch

master cylinder and slave cylinder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective you must first carry out
a function check
⇒ “1.8 Function check for clutch master cylinder and slave
cylinder”, page 20 .
♦ If the slave cylinder is removed from the gearbox with the pipe/
hose assembly still attached, make sure you do not press the
clutch pedal. Otherwise, the piston will be pressed out of the
slave cylinder and be destroyed.
♦ After installing the slave cylinder, press the clutch pedal care‐
fully. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. The plunger of the slave cylinder is likely to have been
guided past the clutch release lever. The slave cylinder would
then be destroyed once pedal force exceeds approx. 300 N.
1.8 Function check for clutch master cylin‐

der and slave cylinder
Before you renew the clutch master or slave cylinder you must -
in the case of the following faults - first carry out the appropriate
checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether withclutch pedal
respect to returns
the correctness all the way
of information in thisto its initial
document. po‐ by AUDI AG.
Copyright
sition, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.

♦ The self-bleeding function of the clutch system can be im‐

paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check for leaks at clutch master and slave cylinder as well as
in the pipe-hose assembly including connections (visual in‐
spection).
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 28 .
High pedal force:
♦ Clutch plate is worn (except for SAC)
♦ Mechanically defective pressure plate/ clutch plate
⇒ page 40
Pedal forces:
Conventional clutch:
- Clutch lining when new: approx. 115 N
- Clutch lining at wear limit: approx. 160 N
Self-adjusting clutch:
- approx. 140 N for complete service life of the clutch
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 28 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.)
♦ Needle bearing in flywheel (centring
Protectedbearing for
by copyright. inputforshaft)
Copying private or commercial purposes, in part or in whole, is not
defective, renew needle bearingpermitted
⇒ Rep. Gr.
unless 13 . by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
♦ Foreign body in clutch system
♦ Mechanically defective pressure plate/ clutch plate
⇒ page 40
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate).
1.9 Removing and installing clutch master

cylinder
♦ Hose clamps, up to Ø 25 mm -3094-

♦ Pliers -V.A.G 1922-
Removing
Note
♦ If you suspect a defective clutch master cylinder, perform the

function test prior to renewing
⇒ “1.7 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 20 .
♦ When performing work in the footwell, put cloths on the carpet
to protect it from possible brake fluid spills.
– Pull off rubber seal on plenum chamber in

-direction of arrow-.
– Detach cover -1- from plenum chamber.
Caution
♦ Follow steps required when disconnecting battery ⇒ Rep.

Gr. 27 .
♦ Make the customer aware that the driver must NOT rest
his/her foot on the clutch pedal for long periods of time.
This could impair the self-bleeding function of the clutch
system as the vent opening in the master cylinder can no
longer function.
– With theProtected
ignition by switched off, for
copyright. Copying disconnect battery
private or commercial earthin part
purposes, strapor in whole, is not
⇒ Rep. Gr. 27unless
permitted . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Use screwdriver to pry off the two caps -3-.

– Unscrew nuts -4- and detach the two wiper arms -2-.
– Pull off clips -1- and detach cowl panel grille -5-.

Take the electronics box out of the plenum chamber as follows:

– Unscrew bolts -arrows- and take off the cover.
– Use screwdriver to carefully
permitted unless authorised by pry
AUDIoff
AG. retaining strap
AUDI AG does -arrow-.
not guarantee or accept any liability
– Lay aside engine control unit with connectors attached.
– Unplug connectors -2- at connector console.

– Unscrew electrical wiring connection -1-.
– Release catches -arrows- and lift auxiliary relay carrier out of

electronics box.
– Pull engine wiring harness together with rubber grommet out
through opening in electronics box.

– Remove nuts -arrows- and lift out electronics box -1-.
Note
♦ In the following steps make sure that no brake fluid escapes

into the plenum chamber or onto the gearbox below. If this
does happen, clean the affected area thoroughly.
♦ When performing work in the footwell, put cloths on the carpet
to protect it from possible brake fluid spills.
– Clamp off supply hose -A- from brake fluid reservoir using
hose clamp -3094- . Disconnect hose from master cylinder and
plug hose.
– Remove rubber grommet from bulkhead above connection
pipe for supply hose.
– Lever out retaining clip -C- using a screwdriver and pull out
pipe/hose assembly -B- slightly.
– Unscrew bolt for brake fluid reservoir -1- and unplug connector
for brake fluid level warning contact -F34- downwards.
Note
The brake fluid reservoir does not have to be removed.
– Remove vacuum pipe leading to brake servo -1-.

– Remove the two Torx bolts -arrows-.
Note
♦ To simplify the illustration, the brake fluid reservoir has not

been included.
♦ The brake fluid reservoir must be swivelled slightly to the side
in order to unscrew the upper Torx bolt. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove storage compartment on driver's side ⇒ Rep. Gr.with respect to the correctness of information in this document. Copyright by AUDI AG.
68 .
– Remove over-centre spring ⇒ page 16 .

– Detach brake pedal from brake servo ⇒ Rep. Gr. 47 .
– Detach steering column from steering box -arrow A- ⇒ Rep.

Gr. 48 .
– Unplug connectors from clutch pedal switch -F 36- -1-, brake
light switch -2- and accelerator pedal module -3-.
– If fitted, unplug connector from clutch pedal switch for engine
start -F194- .
– Unscrew securing bolt for mounting bracket -arrow B- and re‐
move entire pedal cluster.
Release master cylinder operating rod from clutch pedal as fol‐

lows:
Note
♦ When releasing the operating rod, make sure that clutch pedal
does not collide with mounting bracket for clutch pedal switch
-arrow-. The mounting bracket could otherwise break off.
♦ The clutch pedal switch -F 36- ⇒ Item 6 (page 13) and clutch
pedal switch -F 194 - ⇒ Item 14 (page 13) can only be installed
once so as to ensure a firm fit in pedal cluster.
– Apply spark plug connector pliers -V.A.G 1922- in clutch pedal

recesses, press on sides of retaining clip ⇒ Item 9 (page 18)
and detach clutch pedal from clutch master cylinder.

– Detach retaining clip -1- and remove clutch pedal -2-.

– Unscrew bolts -3- and remove master cylinder -4-.
Installing

– Insert master cylinder -4- and tighten bolts -3- to 20 Nm.
– Insert retaining clip -1- in clutch pedal.

– Lock clutch pedal in position by pressing in
-direction of arrow-. Make sure retaining clip -1- engages cor‐
rectly in clutch pedal. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A second mechanic is required for the next step.

– Insert entire pedal cluster and tighten bolt -1- by hand. The
second mechanic should guide the pipe/hose assembly into
the master cylinder from the plenum chamber.

– Tighten bolts for brake servo -arrows- to 25 Nm.
– Press in retaining clip -C- as far as it will go.

– Insert pipe/hose assembly -B- in master cylinder, making sure
you hear it engage.
– Fit rubber grommet -D- onto connecting pipe for supply hose
-A- at bulkhead.
– Push supply hose -A- from brake fluid reservoir on as far as it
will go.
– Remove hose clamp -3094- .
– Screw in securing bolt -1- for brake fluid reservoir and attach
connector at brake fluid level warning contact -F34- .
– Tighten hexagon socket head bolt -arrow B- for securing pedal

cluster to dash panel carrier to 25 Nm.
– Plug in connectors -1-, -2- and -3-.
– If fitted, attach connector for clutch pedal switch for engine
start -F194- .
– Connect brake pedal to brake servo ⇒ Rep. Gr. 47 .
– Secure steering column to steering box -arrow A- ⇒ Rep. Gr.
48 .
– Install over-centre spring ⇒ page 17 .
– Bleed clutch system ⇒ page 28 .

– Insert electronics box and tighten nuts -arrows- to 4 Nm.

– Route engine wiring harness and plug in connector in con‐
nector console.
– Install engine control unit ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .
– If applicable, install auxiliary relay carrier and auxiliary fuse
carrier ⇒ Rep. Gr. 97 .
– Press on cover (hand-tight) and tighten bolts in diagonal se‐
quence to 4 Nm.
– Follow the steps required after connecting the battery ⇒ Rep.
Gr. 27 .
1.10 Bleeding clutch system

♦ Brake filling and bleeding equipment -VAS 5234-
Brake fluid specification ⇒ Rep. Gr. 47 .

Procedure
Note
♦ The clutch system must be bled after performing work on the

hydraulic clutch mechanism.
♦ Before bleeding the clutch system, pull back the clutch pedal
to the normal position and top up brake fluid to “Max” marking
on brake fluid reservoir.
♦ Open the bleeder valve before switching on the bleeding ap‐
pliance.
♦ Do not allow brake fluid to come into contact with the gearbox.
If necessary, clean the gearbox housing.
♦ The clutch system should be bled at the same intervals as the
brake system ⇒ Maintenance ; Booklet 8E .
– Connect brake filling and bleeding equipment -VAS 5234- to

brake fluid reservoir (do not switch on at this stage).
– If fitted, remove noise insulation beneath gearbox.

– If fitted, remove heat shield -arrows- for drive shaft (left-side).
– Connect bleeder hose -A- to clutch slave cylinder -arrow- and
open bleeder valve.
– Connect bleeder hose to pressure hose of fluid collector bottle.
– Switch on bleeding appliance and allow about 100 cm3 of
brake fluid to drain out.
• Operating pressure 2.5 bar
Note
Ensure bleeder hose is correctly fitted during bleeding operation.
– Close bleeder valve.

– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
– Disconnect bleeder hose and fit protective cap.
– Remove brake filling and bleeding equipment -VAS 5234-
from brake fluid reservoir.
– If fitted, screw heat shield for drive shaft (left-side) onto gear‐
box.
Tightening torques
Component Nm
Bleeder valve 4.5
Heat shield for drive shaft to gearbox 23

2 Servicing clutch release mechanism
Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Press tool -VW 412-
♦ Tube -2040- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Torque wrench -V.A.G

1331-
♦ -1- Internal puller -Kukko
21/4-
♦ -4- Counter-support -Kukko
22/1-
♦ Locking fluid -AMV 185 101
A1-
♦ Sealing grease -G 052 128
A1-
♦ Copper grease (commer‐
cially available)
♦ Adhesive -AMV 195 KD1
01-
♦ Grease for clutch plate
splines -G 000 100-

1 - Release bearing
❑ Do not wash out; wipe
clean only
❑ Renew bearing if noisy
❑ Checking release bear‐
ing ⇒ page 32
❑ Servicing release bear‐
ing with glued plastic
ring ⇒ page 32
❑ Checking release bear‐
ing with mechanically
attached plastic ring
⇒ page 33
❑ Retainer lugs on release
bearing must engage in
release lever
2 - Clutch release lever
❑ Before installing, lubri‐
cate area which makes
contact with plunger of
slave cylinder with cop‐
per grease (commer‐
cially available)
3 - Bolt, 35 Nm
❑ 3x
❑ Apply locking fluid -AMV
185 101 A1- when fitting
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide sleeve
❑ Installation position: Oil
drain hole points down‐
wards
❑ Before removing and installing, cover input shaft
Protected by splines with aforshrink-fit
copyright. Copying hose to
private or commercial protect
purposes, oilorseal.
in part in whole, is not
6 - Oil seal with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For input shaft

❑ Pull out of guide sleeve ⇒ Item 5 (page 31) ⇒ page 32 .
❑ Press into guide sleeve ⇒ Item 5 (page 31) ⇒ page 32 .
❑ Pack space between sealing lip and dust lip half full with sealing grease -G 052 128 A1-
7 - O-ring
❑ Always renew
8 - Dished spring
❑ Inner diameter (convex side) faces guide sleeve ⇒ Item 5 (page 31)
9 - Intermediate piece
❑ Installation position: insert locating element between ribs of housing
10 - Ball-head pin
❑ Lubricate with grease for clutch plate splines -G 000 100-
11 - Gearbox
12 - Clutch slave cylinder
❑ Do not operate clutch pedal after slave cylinder has been removed
2. Servicing clutch release mechanism 31

❑ Grease lightly before installing ⇒ page 37

❑ When installing push in until the securing bolt can be fitted.
❑ With plug-in connection for pipe/hose assembly
❑ Disconnecting pipe/hose assembly ⇒ page 37
❑ Follow correct procedure when bleeding ⇒ page 28
❑ Tighten bleeder valve to 4.5 Nm.
❑ Self-locking
❑ Renew
14 - Bracket
❑ For pipe/hose assembly
❑ Bolt onto gearbox with slave cylinder
15 - Plunger
❑ Lubricate end of plunger with copper grease (commercially available)
Pulling oil seal out of guide sleeve

A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 23.5...30 mm , toe.g. -Kukko of21/4-

with respect the correctness information in this document. Copyright by AUDI AG.
Pressing oil seal into guide sleeve (press in onto stop)

• The open side of the oil seal faces towards press tool -VW
454- .
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
2.1 Checking release bearing

Checking and servicing release bearing with glued plastic ring
Identification: inner side of plastic ring has three lugs -arrows-.
The plastic ring may come loose from the release bearing when
the gearbox or release bearing is removed. The release bearing
does not have to be renewed if this happens.
– Before installing the gearbox, glue the loose plastic ring back
onto the bearing with adhesive -AMV 195 KD1 01- .
The three square lugs -arrows- on the plastic ring engage in the
recesses of the bearing ring.
• The release bearing must be renewed if the groove worn on
the plastic ring is deeper than 0.8 mm.

Checking release bearing with mechanically attached plastic ring

Identification: retaining tabs around plastic ring -arrows-.
• The release bearing must be renewed if the plastic ring -1- has
come loose.
• The release bearing -3- must be renewed if the groove
-arrow 2- worn on the plastic ring -1- is deeper than 0.8 mm.
2.2 Removing and installing clutch slave

cylinder
♦ Hose clamps, up to Ø 25 mm -3094-
♦ Lithium grease -G 052 150 A2-

♦ Copper grease (commercially available)
Removing
Observe notes
⇒ “1.7 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 20 .
Note
Do not allow brake fluid to come into contact with the gearbox. If
necessary, clean the gearbox housing.
Caution
If slave cylinder is removed from gearbox with pipe/hose as‐

sembly still attached, make sure you do not press clutch pedal.
Otherwise, the piston will be pressed out of the slave cylinder
and be destroyed.

Vehicles with V6 petrol engine:

– Pull off rear engine cover panel -arrows-.
– Remove cover -1- on left side of engine compartment.
– Unbolt coolant expansion tank -arrow-.

– Unplug electrical wiring leading to coolant shortage indicator
switch -F66- at expansion tank (bottom) and tie up expansion
tank clear to one side (with coolant hoses -1 ... 3- attached).
– If fitted, remove heat shield for connectors from left of bulk‐

head.
– Detach electrical connectors -1 ... 4- from retainer on bulkhead
(left-side).
– Unplug electrical connectors -1- and -4-.
– Move Lambda probe wires clear.
– Remove retainer for connectors.

– Unscrew nut -2- (accessible from above), connecting front ex‐

haust pipe to exhaust manifold on left side.
Note
♦ For illustration purposes here shown with engine removed.

♦ The nuts -1- and -3- (accessible from below) are removed at
a later stage.
Continued for all vehicles:

– Remove front left wheel.
– On vehicles fitted with auxiliary heater, remove bolts
-arrows- securing exhaust pipe of auxiliary/ additional heater
to noise insulation.
– Release fasteners -1 ... 3- and detach noise insulation panels

(front -A- and, if fitted, rear -B-).
Vehicles with V6 petrol engine:

– Unscrew bolts -1 ... 4- and remove front cross piece, if fitted.

Note
The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10° – otherwise it can
be damaged.
– Disconnect exhaust system at clamp (left-side) -left arrow-.
– Unscrew nuts -1- and -3- (accessible Protected

from below) connecting
by copyright. Copying for private or commercial purposes, in part or in whole, is not
front exhaust pipe to exhaust manifoldpermitted
on leftunless
side.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach front exhaust pipe from exhaust manifold on left side
and remove front section of exhaust system.
– If necessary, unbolt drive shaft (left-side) from flange shaft and
move clear to front, taking care not to damage protective coat‐
ing.
– Unscrew nut -arrow- and detach gearbox selector lever from

selector shaft.
– Remove bolt -arrow- and take out clutch slave cylinder from
the rear.
Note
Do not depress clutch pedal after removing clutch slave cylinder.

– Using hose clamp -3094- , clamp off pipe/hose assembly.

– Release retaining clip -A- using a screwdriver and pull out to
limit stop.
– Detach pipe/hose assembly from clutch slave cylinder.
Installing
Note
♦ Renew securing bolt.

♦ When installing, press in slave cylinder so that securing bolt
can be fitted easily.
– Before inserting slave cylinder in gearbox housing, lubricate

area -a- of sleeve with lithium grease -G 052 150 A2- .
– Lightly lubricate surface where plunger and clutch release lev‐
er make contact with copper grease (commercially available).
– Attach bracket -3- for pipe/hose assembly to slave cylinder

-4-.

– Guide slave cylinder -1- into opening in gearbox housing keep‐

ing it as straight as possible (without tilting plunger -arrow A-)
and insert in recess -arrow B- on clutch release lever -3-.
Note
If the slave cylinder -1- is inserted at an angle, there is a danger

that the plunger -arrow A- will be guided past the clutch release
lever -3-.
– Secure slave cylinder with new bolt -2-.
– Press retaining clip -A- in clutch slave cylinder onto limit stop.
– Push pipe/hose assembly onto connection on clutch slave cyl‐
inder so that retainer clip engages audibly.
– Pull pipe/hose assembly to check that it is securely seated.
Caution
♦ After installing the slave cylinder press the clutch pedal

carefully.
♦ If you feel an unusually strong point of resistance when
depressing the clutch pedal,
Protectedyou must Copying
by copyright. not press it down
for private or commercial purposes, in part or in whole, is not
further. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The plunger of the slave cylinder is likely to have been
guided past the clutch release lever.
♦ The slave cylinder would then be destroyed once pedal
force exceeds approx. 300 N.
♦ For comparison: normal pedal force is approx. 115 N.

– Install gearbox selector lever and tighten nut -arrow-.

– If previously removed, attach drive shaft (left-side) to flange
shaft ⇒ Rep. Gr. 40 .
Vehicles with 6-cylinder engine:
– Install front exhaust pipe and perform stress-free alignment ⇒
Rep. Gr. 26 .
– If fitted, install front cross piece ⇒ Rep. Gr. 66 .
– Install heat shield for drive shaft (left-side).
– If the pipe-hose assembly was disconnected at the slave cyl‐
inder, the clutch system has to be bled after installing slave
cylinder ⇒ page 28 .
Tightening torques
Component Nm
Slave cylinder to gearbox 23 1)
Gearbox selector lever to selector shaft 20 2)
• 1) Renew bolt
• 2) Renew nut

3 Servicing clutch
Note
♦ Refer to general repair instructions ⇒ page 6 .

♦ Observe notes on removing and installing clutch master cyl‐
inder and slave cylinder ⇒ page 20 .
♦ On vehicles with SAC pressure plate (self-adjusting clutch,
LuK version) an adjuster ring has to be reset when only the
clutch plate is renewed ⇒ page 52 .
♦ “SAC” stands for “Self-Adjusting Clutch”.
♦ To avoid damaging SAC pressure plate when removing and
installing, observe assembly instructions for SAC pressure
plate ⇒ page 51 .
♦ Check that SAC pressure plate is not distorted ⇒ page 51 .
♦ If the vehicle is fitted with a self-adjusting clutch (Sachs ver‐
sion), the clutch plate and pressure plate can only be renewed
together ⇒ page 44 .
♦ Renew clutch plate and pressure plate if riveted fastening is
damaged or loose.
♦ Select the correct clutch plate and pressure plate according to
engine code ⇒ Electronic parts catalogue .
♦ To avoid damaging dual-mass flywheel during removal,
please observe instructions for removal ⇒ page 47 .
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.
♦ Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
♦ Only blow out dual-mass flywheel with compressed air.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearboxin this document. Copyright by AUDI AG.
with respect to the correctness of information
in order to prevent odours.
Servicing conventional clutch ⇒ page 40

Servicing self-adjusting clutch (Sachs version) ⇒ page 44
Servicing clutch with SAC pressure plate (LuK version)
⇒ page 49
3.1 Servicing conventional clutch

1 - Flywheel/dual mass fly‐

wheel
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. Gr. 13
❑ Do not use a pneumatic
wrench or impact
wrench to remove dual-
mass flywheel
⇒ page 43
2 - Bolt
❑ For flywheel
❑ Tightening torque for
bolt length 22.5 mm:
60 Nm + 90° further
bolt length 43 mm:
❑ Renewing ⇒ Rep. Gr.
13
3 - Clutch plate
❑ The marking
“Getriebeseite” (gear‐
box side), if provided,
faces towards pressure
plate/gearbox
❑ Coil springs (damper
assembly) point to‐
wards pressure plate
and gearbox
❑ Centralising
⇒ page 44
❑ Lightly grease splines ⇒ page 40
❑ Clutch plate diameter ⇒ “1.1 Code letters, allocation, transmission ratios, capacities”, page 1
4 - Pressure plate
❑ Checking ends of diaphragm spring ⇒ page 42 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
❑ Checking springs and riveting ⇒ page 42 with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Checking wire ring ⇒ page 42
❑ Contact surface for clutch lining must be free of grooves, oil and grease
5 - Bolt, 22 Nm
❑ Loosen and tighten gradually in several stages and in diagonal sequence
6 - Needle bearing
❑ Removing and installing ⇒ Rep. Gr. 13
3. Servicing clutch 41
Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Note
When performing repairs always match up clutch pressure plate

and clutch plate by checking engine code ⇒ Electronic parts
catalogue .
Checking springs and riveting

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew pressure plate if springs are broken or badly bent
-arrow B-.
– Check that rivets -arrows B- are secure at all springs

-arrows A-.
• Renew pressure plate if rivets -arrows B- are loose.
Checking wire ring

– Check that wire ring in pressure plate -arrow- is not damaged.
• Renew pressure plate if wire ring is broken.

Removing dual-mass flywheel
Caution
Do not use an impact wrench or pneumatic wrench to remove

bolts -B-: this would severely damage the dual-mass flywheel.
Bolts -B- must always be removed by hand.
– Rotate dual-mass flywheel -A- so that the bolts are aligned

centrally behind the holes -arrows-.
– When removing the bolts, make sure that none of the bolt
heads contacts the dual-mass flywheel, as this would damage
the flywheel when the bolts are unscrewed further.
– Removing and installing dual-mass flywheel ⇒ Rep. Gr. 13 .
3.2 Removing and installing conventional

clutch
♦ Counterhold tool -10-201- or -3067-
♦ Centring mandrel -3176-
♦ Grease for clutch plate splines -G 000 100-

Removing
– Apply counterhold tool -10-201- or -3067- in order to loosen
bolts.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Loosen all bolts consecutively in clockwise direction and in
steps of 90° (1/4 turn) until the pressure plate is released.
Installing
– Apply counterhold tool -10-201- or -3067- in order to tighten
bolts.
• Installation position of clutch plate: coil springs (damper as‐
sembly) or marking “Getriebeseite” point towards pressure
plate and gearbox.
– Use centring mandrel -3176- to centralise clutch plate.
To prevent the pressure plate from becoming distorted during in‐
stallation (causes clutch grab when driving off), always adhere to
the following procedure when installing the pressure plate:
– Position pressure plate on centring pins.
– Screw in all bolts evenly by hand until bolt heads make contact
with pressure plate.
– Tighten all bolts consecutively in clockwise direction and in
steps of 90° (1/4 turn) until housing makes contact with fly‐
wheel.
– Tighten all bolts to final torque (22 Nm) consecutively in clock‐
wise direction.
3.3 Servicing self-adjusting clutch (Sachs version)
Caution
On this type of clutch the pressure plate and clutch plate can
only be renewed together.

1 - Bolt, 22 Nm
❑ Observe instructions for
installation ⇒ page 47
2 - Pressure plate
❑ Self-adjusting
❑ Identification
⇒ page 46
❑ Pressure plate and
clutch plate can only be
renewed together
⇒ page 47
❑ Checking ends of dia‐
phragm spring
⇒ page 46
❑ Checking springs and
riveting ⇒ page 46
❑ Checking wire ring
⇒ page 47
grease
3 - Clutch plate
❑ Pressure plate and
clutch plate can only be
renewed together
❑ The marking
plate/gearbox
❑ If fitted, coil springs
Protected(damper
by copyright.assembly) face
Copying for private or commercial purposes, in part or in whole, is not
permittedtowards pressure
unless authorised by AUDIplate
AG. AUDI AG does not guarantee or accept any liability
and togearbox
with respect the correctness of information in this document. Copyright by AUDI AG.
❑ Centralising ⇒ page 48
4 - Bolt
❑ For flywheel
❑ Tightening torque for bolt length 22.5 mm: 60 Nm + 90° further
❑ Tightening torque for bolt length 43 mm: 60 Nm + 180° further
❑ Renewing ⇒ Rep. Gr. 13
❑ Observe instructions for removal ⇒ page 47
5 - Dual-mass flywheel
❑ Ensure that dowel pins fit tightly
❑ Observe instructions for removal ⇒ page 47
6 - Needle bearing
❑ Removing and installing ⇒ Rep. Gr. 13
Identification
Pressure plate with position sender -arrow-.

• Wear up to half the thickness of the diaphragm spring is per‐
missible.
Note
Important: When performing repairs, always match up pressure

plate and clutch plate by checking engine code ⇒ Electronic parts
catalogue .
Checking spring connection and rivet Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
I - Springs OK with respect to the correctness of information in this document. Copyright by AUDI AG.

tion parts.
-arrow B-.

– Check that rivets -arrows B- are secure at all springs

-arrows A-.
Checking wire ring

– Check that wire ring in pressure plate -arrow- is not damaged.
• Renew pressure plate if wire ring is broken.
Caution

– Rotate flywheel -A- so that bolts -B- are aligned centrally be‐
hind the holes -arrows-.
– When
permitted unscrewing
unless bolts
authorised by AUDI AG. -B-, make
AUDI AG sure
does not the bolt
guarantee heads
or accept do not
any liability
contact
with respect to the flywheelof -arrows-
the correctness information inbecause this
this document. would
Copyright damage
by AUDI AG. the
flywheel when the bolts are turned further.
3.4 Removing and installing self-adjusting

clutch (Sachs version)
♦ Counterhold tool -3067-

– Attach counter-hold tool -3067- or counter-hold tool -10 - 201-
before loosening bolts.

– Loosen all six bolts consecutively in clockwise direction and in
• Stop -2- with position sender -1- should come loose when the
bolts are slackened.
Installing
sembly) or marking “Getriebeseite” point towards pressure
plate and gearbox.
– To remove, reverse position of counter-hold tool -3067- orwith respect to the correctness of information in this document. Copyright by AUDI AG.
counter-hold tool -10 - 201- .


– Make sure that the position sender -arrow- is free to move.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Tighten all six bolts consecutively in clockwise direction and
in steps of 90° (1/4 turn) until the housing makes contact with
flywheel.
– The position sender -arrow- should then lift away from the
pressure plate.
– Tighten all 6 bolts to final torque (22 Nm) consecutively in
clockwise direction.
3.5 Servicing clutch with SAC pressure plate (LuK version)
1 - Dual-mass flywheel
❑ Ensure that dowel pins
fit tightly
grease
removal ⇒ page 51
⇒ Rep. Gr. 13
2 - Needle bearing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Rep. Gr. 13
3 - Bolt
❑ For flywheel
bolt length 22.5 mm:
bolt length 43 mm:
❑ Renewing ⇒ Rep. Gr.
13
removal ⇒ page 47
4 - Clutch plate
❑ The marking
plate/gearbox
❑ Coil springs (damper
assembly) point to‐
wards pressure plate and gearbox
❑ Centralising ⇒ page 52

5 - SAC pressure plate
❑ Observe assembly instructions ⇒ page 51 when removing and installing
❑ Resetting adjuster ring ⇒ page 52
❑ Checking ends of diaphragm spring ⇒ page 50
❑ Checking pressure plate for distortion ⇒ page 51
❑ Checking springs and riveting ⇒ page 50
6 - Bolt, 22 Nm
❑ Observe instructions for installation ⇒ page 51
• Wear up to half the thickness of the diaphragm spring is per‐
missible.
Note
Important: When performing repairs, always match up pressure

plate and clutch plate by checking engine code ⇒ Electronic parts
catalogue .
Checking springs and riveting

I - Springs OK
tion parts.
-arrow B-.
– Check that riveting -arrows B- is secure at all springs

-arrows A-.

Checking SAC pressure plate for distortion, cracks and burning

A - Straightedge
B - Feeler gauge
• Pressure plate distortion up to 1.0 mm is permissible
Caution

– Rotate flywheel -A- so that bolts -B- are aligned centrally be‐
hind theProtected
holes by-arrows-.
– When unscrewing bolts -B-, make sure the bolt heads do not
contact the flywheel -arrows- because this would damage the
flywheel when the bolts are turned further.
3.6 Removing and installing clutch with SAC

pressure plate
♦ Counterhold tool -10 - 201-

Removing
– Attach counterhold tool -10 - 201- before loosening bolts.
– Loosen all six bolts consecutively in clockwise direction and in
Installing
Note
♦ Before you re-install the SAC pressure plate check that it is

not distorted ⇒ page 51 .
♦ When only the clutch plate is renewed, the adjuster ring in the
SAC pressure plate has to be reset before assembly
⇒ page 52 .

sembly) or by
Protected marking “Getriebeseite”
copyright. Copying point towards
for private or commercial pressure
purposes, in part or in whole, is not
platepermitted
and gearbox.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Re-position counterhold tool -10 - 201- to tighten bolts.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Tighten all six bolts consecutively in clockwise direction and
in steps of 90° (1/4 turn) until the housing makes contact with
flywheel.
– Tighten all 6 bolts to final torque (22 Nm) consecutively in
clockwise direction.
3.7 Resetting adjuster ring in SAC pressure

plate
Note
♦ When fitting a new clutch plate in conjunction with a used SAC

pressure plate, the adjuster ring in the pressure plate has to
be reset by turning it back as far as it will go. If you do not reset
the adjuster ring in the pressure plate, the SAC pressure plate
will operate with reduced clamping force, which will cause ex‐
cessive wear, especially of the clutch plate (clutch will then
slip).
♦ If the clutch plate is not renewed, it is not necessary to reset
the adjuster ring.
♦ New SAC pressure plates are pre-set accordingly, and do not
have to be reset.


♦ Thrust pad -3062-
Procedure
– Insert 3 securing bolts for pressure plate -A- into the mounting
holes on the pressure plate at 120° (1/3 turn) intervals, as
shown in the illustration.
– Screw 3 nuts -B- -M8- onto bolts -A- and tighten nuts.
– Place the SAC pressure plate onto the press so that only the
3 bolt heads -arrows- make contact.
– Position thrust pad -3062- in the centre of the pressure plate.
Caution
Do not use force when performing the following steps, as this

could cause the forks on the adjuster ring to break off.
– Apply two screwdrivers to the forks on the adjuster ring. Use

the press tool to apply pressure to the pressure plate until it is
just possible to move the adjuster ring.
– Using the two screwdrivers, turn back the adjuster ring evenly
in -direction of arrows- until it reaches the stop.
– Hold the adjuster ring against
permittedthe stop
unless and relieve
authorised the
by AUDI AG. pressure
AUDI AG does not guarantee or accept any liability
applied by the press so that the adjuster
with respect ring of
to the correctness isinformation
held in inthis
this document. Copyright by AUDI AG.
position.

34 – Controls, housing
1 Servicing selector mechanism
1.1 Installation position of selector mechanism

-Arrow A- gear selection movement
-Arrow B- gate selection movement
1 - Selector rod
2 - Push rod
3 - Connecting rod
4 - Gearbox selector lever
1. Servicing selector mechanism 55

1.2 Exploded view - selector mechanism

Part I
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
5 - Washer
❑ Lip points towards ball
guide
6 - Circlip
❑ Take out before remov‐
ing ball
7 - Spring
8 - Spacer sleeve
9 - Washer
10 - Circlip
11 with
- Noise
respect insulation
to the correctness of information in this document. Copyright by AUDI AG.
❑ -Arrow- marked on
noise insulation points
in direction of travel
12 - Gear knob
❑ With boot
⇒ page 58
13 - Nut, 8 Nm
14 - Gear lever bearing
15 - Bolt, 6 Nm
❑ Secures gear lever
bearing to selector
housing
16 - Gear lever
❑ Bend points towards rear
17 - Bolt
18 - Nut, 8 Nm
19 - Selector housing
20 - Joint body
❑ For selector rod/gear lever
21 - Nut, 10 Nm
❑ Self-locking
❑ Renew
56 Rep. Gr.34 - Controls, housing

22 - Bush
Part II
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Bellows
❑ Secure to selector rod
with commercially avail‐
able instant adhesive
2 - Washer
3 - Ball socket
❑ To remove, bend open
peened points on selec‐
tor rod
⇒ Item 22 (page 58) .
4 - Nut, 10 Nm
5 - Ball stud
6 - Ball socket
❑ To remove pull off re‐
taining clip
⇒ Item 12 (page 57) .
7 - Connecting rod
❑ To remove pull off re‐
taining clip
⇒ Item 12 (page 57) .
8 - Bush
9 - Bush
10 - Bolt, 20 Nm
11 - Sleeve
12 - Retaining clip
13 - Bolt, 40 Nm
14 - Push rod
❑ With bush, bolt and
washers
16 - Washer
17 - Gear lever bearing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
18 - Clamping ring for bellows
19 - Bellows
❑ To remove, carefully pull bellows over selector rod ⇒ Item 22 (page 58) and push rod
⇒ Item 14 (page 57) .
❑ When installing, align with markings on selector rod ⇒ Item 22 (page 58) and push rod
⇒ Item 14 (page 57) .


21 - Clamp
22 - Selector rod
23 - Joint body
❑ For selector rod/gear lever
24 - Cap nut, 20 Nm
25 - Gearbox selector lever
1.3 Removing and installing gear knob with

boot
♦ Hose clip pliers -V.A.G 1275-
Removing
Note
The gear knob is removed together with the gear lever boot and
the cover for the centre console.
– Open ashtray. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unclip cover for centre console and lift it off -arrows-.
Gear knob with clip:

– Pull boot up and over gear knob.
– Open clip -arrow- and pull off gear knob together with boot.

Gear knob with locking mechanism:

– Release connecting piece -1- in direction of -arrow- and pull
gear knob off upwards together with gear lever boot.
Installing
Perform installation in reverse sequence of removal.
1.4 Removing and installing selector mech‐

anism
♦ Engine and gearbox jack -V.A.G 1383 A-
Removing
– Remove gear knob together with boot ⇒ page 58 .
Vehicles with largebyradio
Protected slot:
– Remove operating and
with respect to display of
the correctness unit for airin conditioner
information ⇒ Rep.
this document. Copyright by AUDI AG.
Gr. 87 .
Vehicles with small radio slot:
– First lift trim panel -1- in direction of -arrow A-, then pull it out
in direction of -arrow B-.
– Unscrew bolts -arrows C- and then pull ashtray -2- out of cen‐
tre console.
– Unplug electrical connector for ashtray light.
– Remove foam wedges from centre console.
– Lift out the noise insulation.

– Unscrew noise insulation for selector housing -arrows-.
– Remove nuts -arrows-.

– Loosen bolts/quick-release fasteners -1- and -2- and remove

front noise insulation -A-.
– If fitted, loosen quick-release fasteners -3- and remove rear
noise insulation -B-.


Remove tunnel cross piece (rear) -arrows-.
– Disconnect exhaust system at clamps -arrows-.

– Remove rear section of exhaust system ⇒ Rep. Gr. 26
.
Note
♦ The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10° – otherwise it
can be damaged.
♦ A second mechanic is required for removing the rear section
of the exhaust system.

– Disconnect exhaust system at clamp -2-.
Note
The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.

– Remove tunnel cross piece (front) -1- -arrows-.
– Remove heat shield for exhaust system -4- from below selec‐
tor mechanism.
– Remove universal gearbox support -V.A.G 1359/2- from en‐

gine and gearbox jack -V.A.G 1383 A- and place a wooden
block -arrow- on the lifting column in its place.
Note
You can also insert gearbox support -T10337- in engine and

gearbox jack -V.A.G 1383 A- .
– Support the tunnel cross member (rear) with engine and gear‐
box jack -V.A.G 1383 A- .
– First unscrew bolts -1- and -2-, then bolts -3- and -4-.

– Carefully lower tunnel cross member (rear) with the engine

and gearbox jack -V.A.G 1383 A- until the distance between
cross member (rear) and body reaches dimension “x”.
♦ Dimension x = 60 mm
– Unscrew heat shield -arrow- for drive shaft (right side) and, if
fitted, also for drive shaft (left-side).
– Unscrew connecting rod -2- for selector rod.

– Detach push rod -1-; to do so, unscrew hexagon socket head
bolt.
– Remove nut -arrow- and detach gearbox selector lever from

selector shaft.
– Remove selector mechanism to rear.
Installing
Note
Always renew seals, gaskets and self-locking nuts.

– Place gearbox selector lever in position and secure in place

-arrow-. Tightening torque ⇒ Item 24 (page 58)
– Attach push rod -1-. Tightening torque ⇒ Item 13 (page 57)

– Secure connecting rod -2-. Tightening torque
– Tighten selector housing -arrows-. Tightening torque

– Install tunnel cross member ⇒ Rep. Gr. 40 .
– Install exhaust system and perform stress-free alignment ⇒
Rep. Gr. 26 .
– Adjust selector mechanism ⇒ page 63 .
– Install operating and display unit for air conditioner ⇒ Rep. Gr.
87 .
Tightening torques
Component Nm
Noise insulation to selector mechanism 10
1.5 Adjusting selector mechanism
The following are prerequisites for correct gear lever alignment:

• Gear selector linkage must be in proper condition and undam‐
aged.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
Procedure
– Remove gear knob together with boot ⇒ page 58 .
Vehicles with large radio slot:
– Remove operating and display unit for air conditioner ⇒ Rep.
Gr. 87 .

Vehicles with small radio slot:

– First lift trim panel -1- in direction of -arrow A-, then pull it out
in direction of -arrow B-.
– Unscrew bolts -arrows C- and then pull ashtray -2- out of cen‐
tre console.
– Unplug electrical connector for ashtray light.
– Remove foam wedges from centre console.
– Lift out the noise insulation.
– Unscrew noise insulation for selector housing -arrows-.
– Measure distance -a- between the two studs in the selector

mechanism.
• Specification: distance a = 85 mm
Note
Measure from centre of one stud to centre of the other.
– If distance measured is not correct, adjust dimension -a- as

follows: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Loosen bolt -arrow- for push rod.
• Rear push rod (in selector mechanism) should move freely in

both directions on slide.
– Set to distance -a- by moving rear push rod (in selector mech‐
anism).
– Tighten bolt for push rod -arrow- to 23 Nm.
– Loosen bolt for selector rod -arrow-.

• Connection between selector rod and selector mechanism
should move freely.

Align the gear lever as follows:

– Position bottom of gear lever in centre of ball guide.
• Distance between ball guide and bottom of gear lever
-arrows- must be the same at all points.
– Align gear lever so that it points slightly (1.5°) to the right (as
seen in direction of travel).
– Hold gear lever in this position.
– Tighten bolt for selector rod -arrow- to 23 Nm.
Note
The gear lever must remain in the same position while the bolt is
being tightened.
Checking gear lever setting

• The gear lever should rest in the 3rd/4th gear gate when the
gearbox is in neutral.
– Press clutch pedal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Select all gears several times.
– Check operation of reverse gear lock.
• The gear lever should return by itself from the reverse gear
gate to the 3rd / 4th gear gate.
If the gear lever sticks or baulks repeatedly when engaging a
gear, perform the adjustment procedure again.
– Install trim parts and gear knob ⇒ page 58 .

2 Removing and installing gearbox

♦ Removing gearbox on vehicles with 4-cylinder petrol engine
⇒ page 66 .
♦ Removing gearbox on vehicles with 4-cylinder TDI engine
⇒ page 74 .
♦ Removing gearbox on vehicles with 6-cylinder engine
⇒ page 85 .
♦ Installing gearbox on vehicles with 4-cylinder or 6-cylinder en‐
gine ⇒ page 97 .
2.1 Removing gearbox on vehicles with 4-cylinder petrol engine

equipment required
♦ Support bracket -10-222 A-
♦ Gearbox support -3282-
♦ Adjustment plate -3282/43-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-

♦ Wing compensation plate -T40045-

Procedure
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
♦ Heat insulation sleeves removed during removal of gearbox
Caution

Gr. 27 .
– With ignition switched off, disconnect battery earth strap

-arrow-.
– Remove engine cover panel -arrows-.
2. Removing and installing gearbox 67

– Detach rubber seal from edges of wing mounting flanges.

– To avoid damaging edges of wing panels with support bracket
-10-222 A- , insert wing compensation plates -T40045- on both
sides between the wing mounting flange and the body panel
underneath.
– Set up support bracket -10-222 A- with adapters -10-222/3- on

wing mounting flanges.
– Engage spindles on engine lifting eyes as illustrated.
– Take up weight of engine using spindles.



– Detach bracket -arrow- for noise insulation.
– Unbolt heat shield -arrow- for drive shaft (right-side) from gear‐
box.
– Unbolt drive shafts (left and right) from gearbox flange shafts.
Note

be damaged.
– Separate the exhaust system at the clamp -arrow- and slide

the clamp to rear.
– Unscrew bolt -1- and nut -2- and detach retaining bracket for
front exhaust pipe.

Cabriolet:
Note
On Audi Cabriolet vehicles the following additional steps are re‐

quired in order to remove the three bottom engine/gearbox bolts:
– Unbolt torque reaction support -arrows-.
– Unscrew nuts -1- on left and right sides, and swivel anti-roll
bar -2- downwards.
– Unscrew nuts -3- on engine mountings (left and right) until
bottom of nut is flush with end of stud -arrow-.
– Use support bracket -10-222 A- to lift engine just enough for
nuts -3- to make contact with bottom surface of left and right
console for engine mounting.

– Unscrew the three lower engine/gearbox securing bolts
-arrow-.
Cabriolet:
– Lower engine back down.

– Unbolt starter from engine/gearbox and secure as necessary
⇒ Rep. Gr. 27 .
Note
Starter cables do not have to be disconnected.

– Drill a hole of 10.2 mm ∅ -arrow- in the support elements of

gearbox support -3282- .
– To remove manual gearbox 01X, set up gearbox support

-3282- with adjustment plate -3282/43- and place on engine
and gearbox jack -V.A.G 1383 A- .
Note
♦ The support elements -arrows A- and -arrows B- are shown in

schematic form on the adjustment plate . The arrow on the
adjustment plate pointsProtected
in the bydirection of travel.
♦ Adjustment plate can onlywith
berespect
fittedto the
in correctness
one correct position.
of information in this document. Copyright by AUDI AG.
– Align the adjustment plate parallel to the gearbox.

– Secure support elements to left side of gearbox, as shown in
illustration. Tighten bolt (M10 x 20) -arrow on right side- to
20 Nm.
– Secure support elements to right side of gearbox, as shown in

illustration. Tighten bolt (M10 x 20) -arrow on left side- to
20 Nm.

– First remove bolts -1- and then bolts -2-.
– Unscrew nuts -arrows- and detach tunnel cross member.

– Lower gearbox slightly with engine and gearbox jack -V.A.G
1383 A- .
– Unplug electrical connector -arrow- for reversing light switch -
F4- and move electrical wire clear.

– Unscrew push rod -1-, using an 8 mm hexagon key when un‐
screwing bolt.


selector shaft.
– Remove upper engine/gearbox securing bolts -arrows 1- and

-arrows 2-. Please note that retaining brackets for wires/lines
and coolant pipe may be secured on bolts -arrows 2- (impor‐
tant for installation).
– If fitted, remove retaining clips/cable ties together with Lambda
probe wiring from gearbox.
– Remove remaining engine/gearbox securing bolts -arrow A-

and -arrow B-.
– Press gearbox off dowel sleeves and lower carefully with en‐
gine and gearbox jack -V.A.G 1383 A- just far enough to gain
access to clutch slave cylinder.
Note
When lowering gearbox, ensure hydraulic pipe/hose to slave cyl‐

inder is not damaged.

– Remove clutch slave cylinder from gearbox -arrow- and se‐

cure with wire, do not open pipe/hose system.
Caution
Do not depress clutch pedal after removing clutch slave cylin‐

der. The slave cylinder would then be destroyed once pedal
– Lower gearbox completely with engine and gearbox jack -

V.A.G 1383 A- .
Note
♦ Make sure that all wiring has been detached from top of gear‐
box.
♦ When lowering gearbox, make sure there is sufficient clear‐
ance from drive shafts.
– Before carrying out assembly work, secure gearbox to assem‐

bly stand , using engine and gearbox support -VW 540-
⇒ page 111 .
– If you will be installing a new gearbox instead of the one re‐

moved, the gearbox mounting has to be transferred to the new
gearbox -arrows- ⇒ page 109 .
Installing gearbox ⇒ page 97
2.2 Removing gearbox on vehicles with 4-cylinder TDI engine


equipment required
1331-
1332-
V.A.G 1383 A-
♦ Wing compensation plate -T40045-


Procedure
Note
Caution

Gr. 27 .

-arrow-.
Vehicles with 1.9 ltr. TDI engine:

– Pull dipstick -1- out of guide tube.
– Unclip caps.
– Unscrew nuts -arrows- and detach engine cover.
– Remove insulation from beneath cover.
– Re-insert dipstick in guide tube.

– Pull off engine cover panel -arrows-.


– Unplug electrical connector for coolant shortage indicator
switch -F66- at expansion tank (bottom) and move coolant ex‐
pansion tank (with coolant hoses -1 … 3- attached) clear to
one side.
– If fitted, remove air cleaner cover -arrow-.
– Remove bolts -arrows-.

– Remove air ducts -1- and -2-.
– Unplug electrical connector -2- at air mass meter -G70- .

– Move wiring harness clear at air cleaner housing -arrows-.
– Detach air hose -3-.
– Unscrew bolt -1- and take out air cleaner housing.


– Move clear electrical wiring at fuel filter bracket.
– Unscrew nuts -arrows- and move fuel filter aside (with fuel ho‐
ses attached).

– Remove upper engine/gearbox securing bolts -arrows 1- and
-arrows 2-. Please note that there may be brackets for wires/
lines located beneath the bolts -arrows 2- (important for in‐
stallation).

underneath.
– Set up support bracket -10-222 A- with adapters
permitted -10-222/3-
unless authorised by AUDIonAG. AUDI AG does not guarantee or accept any liability
wing mounting flanges. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Engage spindles on engine lifting eyes as illustrated.

– Take up weight of engine using spindles.



– If fitted, loosen quick-release fasteners -3-authorised
permitted unless and remove
by AUDI AG.rear
AUDI AG does not guarantee or accept any liability
noise insulation -B-. with respect to the correctness of information in this document. Copyright by AUDI AG.
Vehicles with particulate filter

– Unscrew bolts for front exhaust pipe bracket -arrows-.
– Remove front exhaust pipe behind particulate filter ⇒ Rep. Gr.
26 .


– Remove noise insulation -1- in wheel housing (left and right).
– Unbolt heat shield -arrow- for drive shaft (right-side)
with respect from gear‐
to the correctness of information in this document. Copyright by AUDI AG.
box.
– Unbolt drive shafts (left and right) from gearbox flange shafts.
– Unscrew bolt -1- and nut -2-, and detach retaining bracket for
front exhaust pipe (if fitted).
Note

be damaged.
– Separate the exhaust system at the clamp -arrow- and slide

the clamp to rear.

Cabriolet:
Note
On Audi Cabriolet vehicles the following additional steps are re‐

quired in order to remove the three bottom engine/gearbox bolts:
– Unbolt torque reaction support -arrows-.
– Unscrew nuts -1- on left and right sides, and swivel anti-roll
bar -2- downwards.
– Unscrew nuts -3- on engine mountings (left and right) until
bottom of nut is flush with end of stud -arrow-.
– Use support bracket -10-222 A- to lift engine just enough for
nuts -3- to make contact with bottom surface of left and right
console for engine mounting.

– Unscrew the three lower engine/gearbox securing bolts
-arrow-.
Cabriolet:

⇒ Rep. Gr. 27 .
Note

– Drill a hole of 10.2 mm ∅ -arrow- in the support elements of

gearbox support -3282- .

-3282- with adjustment plate -3282/43- and place on engine
Note

adjustment plate points in the direction of travel.
♦ Adjustment plate can only be fitted in one correct position.

20permitted
Nm. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

20 Nm.

– First remove bolts -1- and then bolts -2-.
– Unscrew nuts -arrows- and detach tunnel cross member.

– Lower gearbox slightly with engine and gearbox jack -V.A.G
1383 A- .

F4- and move electrical wire clear.

– Unscrew push rod -1-, using an 8 mm hexagon key when un‐
screwing bolt.


selector shaft.
– Move wiring clear at top of gearbox.

and -arrow B-.
Note


Caution

– If fitted, remove retaining clips/cable ties together with Lambda

probe wires from top of gearbox.
– Lower gearbox.
Note
When lowering gearbox, make sure there is sufficient clearance

from drive shafts.

⇒ page 111 .


2.3 Removing gearbox on vehicles with 6-cylinder engine

equipment required
1331-
1332-
V.A.G 1383 A-

♦ Lifting tackle -2024 A-

Procedure
Note
Caution
Follow steps required when disconnecting battery ⇒ Rep. Gr.

27 .

-arrow-.
Vehicles with 6-cylinder 2.4 ltr. engine:

– Remove engine cover panel -arrows-.

Vehicles with 6-cylinder 3.0 ltr. engine:

– Pull off rear engine cover -arrows-.
– Pull off front engine cover -arrows-.

– Remove cover -1- on left side of engine compartment.

– Unplug electrical connector for coolant shortage indicator
switch -F66- at expansion tank (bottom) and move coolant ex‐
pansion tank (with coolant hoses -1 … 3- attached) clear to
one side.

– Remove cover -1- on right side of engine compartment.
– Remove bolts -arrows- from solenoid valve mounting plate

-3-.
– Detach air intake hose -1- from air-mass meter .
– Pull hose -4- for crankcase breather system off air duct -2-.
– Unscrew bolt -arrow- and disconnect air duct -2- from throttle
valve module -J338- .
– If fitted, detach hose -1- from air duct.
Note
In the illustration, the air duct is shown from the rear and with the
engine removed.
– Unscrew engine/gearbox securing bolts which are accessible

from above.
– Detach connectors -1 ... 4- from retainer at left side of bulk‐

head.
– Unplug electrical connectors -1- and -4-.
– Move Lambda probe wires clear.
– Remove retainer for connectors.

– Unscrew nut -2- (access from above), connecting left front ex‐
haust pipe with exhaust manifold.
Note
♦ For illustration purposes here shown with engine removed.

♦ The nuts -1- and -3- (accessible from below) are removed at
a later stage.

underneath.
– Set up
support bracket -10-222 A- on wing mounting flanges.

– Remove eye of lifting tackle -2024 A- .

– Re-insert pin -1- in middle hole on lifting tackle and secure it
with split pin.
– Hook pin on lifting tackle -2024 A- onto spindle on support
bracket -10-222 A- .
– Hook lifting tackle -2024 A- into lifting eyes at front and rear of
engine.
WARNING
Support hooks and locking pins on lifting tackle must be se‐

cured with retainers -arrows- in illustration.
– Slightly pretension engine with spindle of support bracket .


– If fitted, loosen quick-release fasteners -3-Protected
and remove rear
noise insulation -B-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Remove heat shield -arrow- for drive shafts (left and right).
– If fitted, remove tunnel cross member (front) -1 ... 4-.

– Remove front exhaust pipe (left-side) with catalytic converter
⇒ Rep. Gr. 26 .
– Remove bracket for exhaust pipe (front right) from gearbox.
– Unscrew nuts -1- at bottom of engine mountings (left and

right).

– If fitted, unclip operating rod for vehicle level sender -G78-

from lower transverse link -arrow-.
– Before loosening the subframe, use locating pins -3393- to

check whether holes -1- and -2- are aligned.
If this is not the case, wheel alignment has to be performed after
installing the subframe.
– First remove front bolts -2- and -3- on subframe (left and right).
Then remove bolts -1-.
– Lower subframe at the front.
– Unscrew bottom engine/gearbox securing bolts -arrows-.

– Temporarily secure subframe again.

Temporary tightening torque:
1 - approx. 100 Nm
2 - approx. 70 Nm
3 - approx. 70 Nm
Caution
Do not renew bolts yet or tighten to their final torque. This will
be done when installing the gearbox.
– Remove drive shafts -1- from flange shafts and tie up to side.
Note
Make sure you do not damage surface coating on drive shafts.
– Support gearbox with engine and gearbox jack -V.A.G 1383

A- .
– First remove bolts -2- and then bolts -3- at tunnel cross mem‐
ber.
– Unscrew the two nutspermitted
-4- and detach
unless tunnel
authorised cross
by AUDI member.
AG. AUDI AG does not guarantee or accept any liability
– Carefully lower engine and gearbox jack -V.A.G 1383 A- and
move it aside.

– Detach push rod -1-; to do so, unscrew hexagon socket head
bolt.
– Detach connector -arrow- for reversing light switch -F4- at right

side of gearbox.


selector shaft.
– Open cable ties -arrows A and B-, unclip Lambda probe wiring
at side -arrows C- and move wiring clear.

⇒ Rep. Gr. 27 .
Note
– If fitted, remove engine speed sender -G28- from left side of

gearbox -arrow- and lay aside.

– Unscrew upper engine/gearbox securing bolts as well as

those on the side, except for bolts marked with -arrow A- and
-arrow B-.
–Protected
Drillbyacopyright.
hole ofCopying
10.2 for
mm ∅ -arrow- in the support elements of
gearbox supportby-3282-
AUDI AG.. AUDI AG does not guarantee or accept any liability
private or commercial purposes, in part or in whole, is not
permitted unless authorised

-3282- with adjustment plate -3282 /43- and place on engine
Note

adjustment plate points in the direction of travel.
♦ Adjustment plate can only be fitted in one correct position.

20 Nm.


20 Nm.

and -arrow B-.
Note


Caution

– Lower gearbox.
Note
When lowering gearbox, make sure there is sufficient clearance

from drive shafts.

⇒ page 111 .


2.4 Installing gearbox on vehicles with 4-

cylinder or 6-cylinder engine
– Use a thread tap to remove any remaining locking fluid from
all threaded holes which will accommodate self-locking bolts.
– Always renew self-locking bolts and nuts.
– Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Do not grease guide sleeve.
It should be possible to push the clutch plate back and forth slight‐
ly on the input shaft.
– Check clutch release bearing for wear and renew if necessary
⇒ page 32 .
– If plastic ring -arrows- has come loose, service release bearing
as required ⇒ page 32 .
– Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block, install if necessary.
– Place intermediate plate on dowel sleeves at engine flange.
– Before installing gearbox, tie electrical wires and brackets off
to one side so that they are not trapped between the engine
and the gearbox.
– Lightly lubricate surface
with respect to the where plunger
correctness andin clutch
of information release
this document. lev‐by AUDI AG.
Copyright
er make contact -arrow B- using grease -Z 381 351 TE- .
– Raise gearbox far enough to be able to install clutch slave cyl‐
inder with bracket for pipe/hose assembly.
– Guide slave cylinder -1- into opening in gearbox housing keep‐
ing it as straight as possible (without tilting plunger -arrow A-)
and insert in recess -arrow B- on clutch release lever -3-.
Note
If the slave cylinder -1- is inserted at an angle, there is a danger

that the plunger -arrow A- will be guided past the clutch release
lever -3-.

– Secure clutch slave cylinder with new bolt -arrow-.
Caution
After installing the slave cylinder press the clutch pedal care‐
fully. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down further.
The plunger of the slave cylinder is likely to have been guided
past the clutch release lever. The slave cylinder would then be
destroyed once pedal force exceeds approx. 300 N.
– Insert gearbox, making sure there is sufficient clearance to

drive shafts.
– Install engine/gearbox securing bolts -arrow A- and

-arrow B-.
– Install starter ⇒ Rep. Gr. 27 .
– Carefully lower gearbox a short distance using engine and

– If possible, tighten upper engine/gearbox securing bolts
-arrows 1- and -arrows 2-.

– If fitted, secure all electrical wiring to gearbox again

-arrows A ... C-.
– If fitted, install engine speed sender -G28- on left side of gear‐

box.
– Install gearbox selector lever and tighten nut -arrow-.
– Install push rod -1-; to do so, tighten hexagon socket head bolt.
– Secure connecting rod -2- for selector rod.

– Attach electrical connector -arrow- for reversing light switch -

F4- on gearbox (right side).
– Lift gearbox again using engine and gearbox jack -V.A.G 1383
A- .
– Attach tunnel cross member to body with bolts -2- and -3-
(tighten hand-tight only).
Note
Renew bolts -3-.
– Bolt tunnel cross member onto gearbox mounting -4- ⇒ Rep.

Gr. 40 .
– Carefully lower engine and gearbox jack -V.A.G 1383 A- and
move it aside.
– Attach drive shafts -1- to flange shafts ⇒ Rep. Gr. 40 .
Cabriolet vehicles with 4-cylinder engine:

– Lift engine slightly using spindles.
– Tighten the bottom engine/gearbox securing bolts -arrows-.


– Secure torque reaction support -arrows-.
– Tighten nuts -3- for engine mountings ⇒ Rep. Gr. 10 .

– Secure anti-roll bar -2- with nuts -1- ⇒ Rep. Gr. 40 .
Vehicles with 6-cylinder petrol engine:

• Weight of engine is partly taken up with support bracket -10 -
222 A- ⇒ page 89 .
– First remove front bolts -2- and -3- on subframe (left and right).
Then remove bolts -1-.
– Lower subframe at the front.
– Tighten three bottom engine/gearbox securing bolts

-arrows-.

– Renew the front subframe bolts -1-, -2- and -3- on both sides
of the vehicle.
Before tightening subframe, it must be aligned with body using

locating pins -3393- .
• Hole -1-, hole -2- in subframe and hole -3- in aluminium brack‐
et must be inProtected
alignment on both sides.
Note
This alignment can only replace a subsequent wheel alignment if

holes -1- and -2- coincided before the repair work was carried out.
– Secure subframe ⇒ Rep. Gr. 40 .
– Tighten nuts -1- for engine mountings ⇒ Rep. Gr. 10 .

– Secure tunnel cross member ⇒ Rep. Gr. 40 .
– Install exhaust system and align free of stress ⇒ Rep. Gr. 26 .
– Check selector mechanism setting and adjust if necessary
⇒ page 63 .
– Check gear oil level in gearbox ⇒ page 110 .
– Follow the steps required after connecting the battery ⇒ Rep.
Gr. 27 .
– Check and adjust wheel alignment if necessary ⇒ Rep. Gr.
44 .
♦ Wheel alignment is not necessary if subframe was located in
relation to body using locating pins -3393- prior to dismantling
and assembly of subframe (before tightening bolts).
♦ Wheel alignment must, however, be carried out if the subframe
was not located in relation to the body using locating pins
-3393- or if it was not possible to fully insert the two pins into
the holes.
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine or gearbox oil may be
used, but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques ±15%.

Engine/gearbox attachment (2.0 ltr. petrol engine)

Item Bolt Nm
1 1) M12 x 75 65
2 1) M12 x 90 65
3 2) M12 x 75 65
4, 6 M12 x 90 65
5 2) M12 x 110 65
7 3) M10 x 50 45
8, 9, 10 M10 x 45 45
11 4) M12 x 110 65
A Dowel sleeves for centralising
1) Secures starter to gearbox
2) With bracket for wiring harness
3) Hammer head bolt with nut
4) With nut
Engine/gearbox attachment (1.9 ltr. TDI engine)

Item Bolt Nm
1 1) M12 x 80 65
2 1) M12 x 95 65
3 2) M12 x 80 65
4, 6 M12 x 95 65
5 2) M12 x 110 65
7 3) M10 x 50 45
8, 9, 10 M10 x 45 45
11 4) M12 x 110 65
4) With nut

Engine/gearbox attachment (2.0 ltr. TDI engine)

Item Bolt Nm
1 1) M12 x 105 65
2 2) M12 x 80 65
3 2) M12 x 90 65
4 3) M12 x 80 65
5, 7 M12 x 95 65
6 3) M12 x 105 65
8 4) M10 x 50 45
9, 10, 11 M10 x 45 45
1) With nut
Engine/gearbox attachment (6-cylinder 2.4 ltr. petrol engine)

Item Bolt Nm
1, 9, 10, 11 M10 x 60 45
2 1) M10 x 150 65
3 M12 x 130 65by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
4…6 M12 x 80 65
7 M12 x 100 65
8 M12 x 90 65
1) Property class 10.9

Engine/gearbox attachment (6-cylinder 3.0 ltr. petrol engine)

Item Bolt Nm
1, 10, 11 M10 x 60 45
2 1) 2) M10 x 150 65
3 1) M12 x 130 65
4 M12 x 85 65
5, 6 M12 x 90 65
7 M10 x 100 45
8 M12 x 95 65
9 3) M10 x 60 45
2) Property class 10.9
Component Nm
Slave cylinder to gearbox 23 1)
Gearbox selector lever to gearbox 20
Push rod to gearbox 40
Connecting rod for selector rod to gearbox 20
Gearbox mounting to gearbox 23
Tunnel cross member
Protected byto gearbox
copyright. mounting
Copying 23 in part or in whole, is not
for private or commercial purposes,
Heat shields above drive shafts to gearbox 23
Engine mounting to engine support 23
Torque reaction support to engine (Cabriolet 30 + 90° 1)
only)
Bracket for noise insulation to subframe 10
1) Renew bolt
2.5 Transporting gearbox

♦ Lifting aid -T40013-

♦ Workshop hoist -VAS 6100-
Procedure
– Insert lifting aid -T40013- in lifting eye on gearbox and secure.
– Engage hook of workshop hoist in 4th notch -arrow- on lifting
aid .
– Lift gearbox with workshop hoist and lifting aid -T40013-
Protected by copyright. .Copying for private or commercial purposes, in part or in whole, is not

3 Removing and installing gearbox

mounting
♦ Engine and gearbox jack -V.A.G 1383 A-
Removing
– Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox

up slightly. Insert a wooden block -1- between gearbox and
gearbox jack.
Note
You can also insert gearbox support -T10337- in engine and

3. Removing and installing gearbox mounting 107

– First remove bolts -3- and then bolts -2- at tunnel cross mem‐
ber.
– Lower gearbox slightly.
– Unscrew the two nuts -1- and push tunnel cross member
backwards slightly.
– Unscrew gearbox mounting -arrows-.
Installing
– Bolt gearbox mounting to gearbox -arrows- and tighten to
specified torque.
– Bolt tunnel cross member onto gearbox mounting -arrows-.

– Lift gearbox until bolts -2- can be fitted.

– First tighten bolts -2- and then bolts -1- ⇒ Rep. Gr. 40 .
Note
Renew bolts -2-.
– Align exhaust system so it is free of stress ⇒ Rep. Gr. 26 .

Tightening torques
Component Nm
Gearbox mounting to gearbox 23
Tunnel cross member to gearbox mounting 23
Clamp for exhaust pipe 40
3. Removing and installing gearbox mounting 109

4 Checking oil level in manual gearbox

Procedure
Note
The vehicle must be horizontal when checking gear oil level.
– To check gear oil level, unscrew oil filler plug -arrow-.
The oil level is correct when gearbox is filled up to edge of housing

-arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Top up with gear oil if necessary. Specification
with respect to the correctness⇒of page 1 .in this document. Copyright by AUDI AG.
information
– Screw in oil filler plug and tighten.
Note the following when filling with new oil:

– Remove oil filler plug -arrow-.
– Fill with gear oil up to edge of housing -arrow-.

– Screw in oil filler plug.
– Start engine, engage a gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Switch off engine and remove oil filler plug.
Once more, fill with gear oil up to edge of housing -arrow-.
– Screw in oil filler plug and tighten.
Tightening torque
Component Nm
Oil filler plug 45

5 Mounting gearbox on assembly stand

equipment required
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Workshop hoist -
VAS 6100-
♦ Lifting aid -T40013-
Procedure
– Insert lifting aid -T40013- in lifting eye on gearbox and secure.
– Fasten hook of workshop crane -VAS 6100- in 4th notch
-arrow- on lifting tackle -T40013- .
– Lift gearbox with workshop hoist -VAS 6100- and lifting aid -
T40013- .
5. Mounting gearbox on assembly stand 111

– Secure engine and gearbox support -VW 540- to gearbox and

fit into support clamp -VW 313- .

6 Dismantling and assembling gearbox

⇒ “6.1 General layout of gearbox”, page 113
⇒ “6.2 Exploded view - dismantling and assembling gearbox”,
page 114
⇒ “6.3 Exploded view - removing and installing ball bearing for
input shaft, gearbox cover, bearing housing and selector shaft”,
page 114
⇒ “6.4 Exploded view - removing and installing 3rd to 6th gear”,
page 116
⇒ “6.5 Exploded view - removing and installing input shaft, output
shaft, reverse gear wheel and reverse selector gear”, page 119
⇒ “6.6 Assembly sequence - dismantling and assembling gear‐
box”, page 120
6.1 General layout of gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Reverse gear
9 - Gearbox cover
10 - Bearing housing
11 - Gearbox housing
12 - Ball bearing
❑ For input shaft
13 - Input shaft (main shaft)
14 - Differential
6. Dismantling and assembling gearbox 113

6.2 Exploded view - dismantling and assembling gearbox

Sequence for dismantling and assembling
box”, page 120
1 - Exploded view - gearbox

housing with differential, ball
bearing for input shaft and se‐
lector shaft
ball bearing for input
shaft, gearbox cover,
bearing housing and se‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
lector shaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 114 with respect to the correctness of information in this document. Copyright by AUDI AG.

differential ⇒ page 199
❑ Servicing gearbox
housing ⇒ page 153
2 - Exploded view - bearing
housing with gear assembly
3rd to 6th gear
⇒ page 116
input shaft, output shaft
with selector gear for 1st
and 2nd gear, reverse
gear wheel and reverse
selector gear
⇒ page 119
3 - Exploded view - gearbox
cover
❑ Servicing ⇒ page 142
6.3 Exploded view - removing and installing

ball bearing for input shaft, gearbox cov‐
er, bearing housing and selector shaft
box”, page 120

1 - Bolt, 35 Nm
❑ 3x
❑ Apply locking fluid -AMV
185 101 A1- when fitting
2 - Guide sleeve
❑ With oil seal
3 - O-ring
❑ Always renew
4 - Dished spring
❑ Smaller diameter (con‐
vex side) faces guide
sleeve
⇒ Item 2 (page 115) .
5 - Circlip
❑ Note thickness
❑ Re-determining thick‐
ness
⇒ “1.3 Adjusting input
shaft”, page 173
6 - Ball bearing
⇒ page 120
7 - Circlip
❑ Note thickness
ness
shaft”, page 173
8 - Locking bolt, 45 Nm
❑ 2x
❑ Apply locking fluid -AMV 185 101 A1- when fitting
9 - Dowel sleeve
❑ 2x
❑ Insert in gearbox housing
❑ Remove and install with drift -3121-
10 - Selector shaft with selector cylinder
11 - O-ring
❑ For selector shaft cover
❑ Always renew
❑ Lubricate with gear oil Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Selector shaft cover with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ With reversing light switch -F4-

13 - Bolt, 24 Nm
❑ 3x
❑ Apply locking fluid -AMV 185 101 A1- when fitting

14 - Reversing light switch -F4- , 20 Nm

15 - Pin
❑ For selector shaft stop
❑ Insert in gearbox housing
❑ Installation position: groove on threaded pin points towards selector shaft cover
16 - Dowel sleeve
❑ 2x
❑ Insert in bearing housing
❑ Remove and install with drift -3121-
17 - Gearbox cover
Note
If only the gearbox cover is removed

from the manual gearbox, the bear‐
ing housing ⇒ Item 19 (page 116)
must be removed as well so that
new sealant can be applied be‐
tween gearbox housing and bearing
housing.
18 - Bolt, 35 Nm + 90° further

❑ 12x
❑ Removing and installing 3rd to 6th gear ⇒ page 116
❑ Removing and installing input shaft, output shaft with selector gear for 1st and 2nd gear, reverse gear
wheel and reverse selector gear ⇒ page 119
20 - Gearbox housing
❑ With differential and flange shafts
❑ Removing and installing differential ⇒ page 199
❑ Servicing gearbox housing ⇒ page 153
21 - Oil drain plug, 45 Nm
22 - Oil filler plug, 45 Nm

3rd to 6th gear
box”, page 120
Note
3rd to 6th speed selector gears should have an axial play of 0.20 ... 0.50 mm after installing.

1 - Bearing housing
❑ With input shaft and out‐
put shaft
2 - Oil collector
❑ With magnet
❑ Clipped into reverse
shaft support.
3 - Circlip
❑ Install the thickest circlip
that will still just fit.
ness ⇒ page 120
4 - 6th gear wheel
❑ Installation position:
high inside collar faces
spacer sleeve
5 - Spacer sleeve
6 - 5th gear wheel
4th gear wheel
7 - 4th gear wheel
5th gear wheel
8 - Circlip
❑ Install the thickest circlip
that will still just fit.
ness ⇒ page 120
9 - 3rd gear wheel
❑ Installation position: machined side faces reverse gear synchronising hub
10 - Selector rod for 3rd and 4th gear
❑ When combined with spring-loaded selector fork, lock washer ⇒ Item 23 (page 118) must engage behind
shoulder -arrow-
11 - Selector rod for 5th and 6th gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Thrust washer with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For 3rd speed selector gear

13 - Needle bearing
❑ For 3rd gear
14 - 3rd speed selector gear
❑ Insert spring before installing ⇒ page 172
❑ Check axial clearance after installing using feeler gauge (0.20 ... 0.50 mm)
15 - 3rd gear synchro-ring
❑ Checking for wear ⇒ page 172
16 - Circlip
❑ Mark
❑ Do not interchange with other circlip ⇒ Item 18 (page 118)

17 - Synchronising hub for 3rd and 4th gear

❑ Installation position: high inside collar faces 3rd speed selector gear
18 - Circlip
❑ Re-determining thickness ⇒ page 120
19 - Locking collar for 3rd and 4th gear
❑ Mark position in relation to synchronising hub prior to removing
20 - Selector fork for 3rd and 4th gear
21 - Pin with clip
❑ For securing selector fork for 3rd and 4th gear to selector rod
22 - Spring
❑ Not fitted on all versions
23 - Lock washer
❑ Must engage below shoulder -arrow- on selector rod for 3rd and 4th gear
❑ Not fitted on all versions
❑ Always renew
24 - 4th gear synchro-ring
25 - 4th speed selector gear
26 - Needle bearing
❑ For 4th gear
27 - Thrust washer
❑ For 4th speed and 5th speed selector gears
28 - Needle bearing inner race
❑ For 5th gear
29 - Needle bearing
❑ For 5th gear
32 - Synchronising hub for 5th and 6th gear
33 - Locking collar for 5th and 6th gear
34 - Needle bearing inner race Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For 6th gear

35 - Needle bearing
❑ For 6th gear


38 - Thrust washer
❑ For 6th speed selector gear
39 - Inner race
❑ For needle roller bearing
40 - Multi-point socket head bolt, 150 Nm
41 - Selector fork for 5th and 6th gear
42 - Pin with clip
❑ For securing selector fork for 5th and 6th gear to selector rod

input shaft, output shaft, reverse gear
wheel and reverse selector gear
box”, page 120 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Bearing housing
2 - Reverse gear wheel
❑ With support for reverse
shaft
❑ Exploded view - reverse
gear wheel
⇒ page 120
3 - Bolt, 30 Nm
❑ 3x
4 - Reverse gear selector fork
5 - Pin with clip
❑ For securing reverse
gear selector fork to se‐
lector rod
6 - Reverse gear locking collar
❑ Mark position in relation
to synchronising hub
prior to removing
taper faces reverse gear
synchro-ring
7 - Reverse gear synchronis‐
ing hub
3rd gear wheel
8 - Synchro-ring for reverse
gear
❑ Checking for wear
⇒ page 180

9 - Reverse selector gear

❑ Insert spring before in‐
stalling ⇒ page 180
10 - Needle bearing
❑ For reverse gear
❑ With tapered roller bearing and selector gears for 1st and 2nd speed
❑ Dismantling and assembling ⇒ page 180
12 - Input shaft
❑ Dismantling and assembling ⇒ page 169
Exploded view - reverse gear wheel

1- Thrust washer
2- Needle bearing
3- Reverse gear wheel
Installation position: collar points towards bearing housing
4 - Reverse shaft support
6.6 Assembly sequence - dismantling and

assembling gearbox
Removing and installing ball bearing for input shaft, selector shaft,
gearbox cover and bearing housing with input shaft and pinion
shaft.


equipment required
♦ Drift sleeve -VW 244 B-
♦ Tube -VW 415 A-

♦ Tube -VW 519-

♦ Engine and gearbox sup‐
port -VW 540-
♦ Extension -30 - 23-
♦ Press tool -40 - 21-
♦ Support -40 - 103-
♦ Thrust plate -40 - 105-

♦ Drift sleeve -41 - 501-

♦ Gearbox bracket -2004-
♦ Locking pin -2064-
♦ Thrust piece -3002-
♦ Door hinge alignment tool
(M8 and M10) -3114/2-
♦ Fitting tool -T10246-

♦ Workshop press -V.A.G

1290 A-
♦ Drip tray -V.A.G 1306-
1331-
1332-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/12-
21/2-
♦ -2- Puller -Kukko 18/2-

♦ Plate -T40086-
♦ Plate -T40088/1-
♦ -1- Two-arm puller -Kukko
20/10-
♦ -2- Puller hook, length 200
mm
♦ -2- Puller hook, length 250
mm
♦ Engine and gearbox support supplement -VW 540/1 B-

♦ Hot air blower -V.A.G 1416-
♦ Inductive heater -VAS 6414-
♦ Feeler gauge
♦ 2 bolts M8 (length 70 mm) with washers
♦ Sealing paste -AMV 188 001 02-
♦ Assembly sleeve -01E 311 120-
♦ Locking fluid -AMV 185 101 A1-
Dismantling gearbox
– Mount gearbox on assembly stand.
– Place drip tray , e.g. -V.A.G 1306- , under gearbox.
– Drain gear oil.
– Remove clutch release lever -A- together with release bearing.

– Remove guide sleeve -B-
– Remove dished spring -C-.
– Then remove circlip -D- in front of ball bearing for input shaft.
Note
If the input shaft or gearbox housing is not to be renewed, note

the thickness of the circlip.

– Pull the ball bearing for input shaft out of gearbox housing.
– Remove the circlip -arrow- behind the ball bearing for input
shaft.
Note
If the input shaft or gearbox housing is not to be renewed, note

the thickness of the circlip.
– Remove bolts -arrows- and take off selector shaft cover -A-.
– Unscrew the two locking bolts -1- for selector shaft.

• Make sure that no gear has been engaged.
– Push selector shaft -2- into gearbox as far as it will go, simul‐
taneously removing pin -3-.
– Pull out selector shaft.

– Move two selector rods -arrow A- and -arrow B- to lock input

shaft by selecting two gears (e.g. reverse gear and 1st gear).
– Unscrew securing bolts for gearbox cover -arrows-.

– Carefully pull off gearbox cover -A- towards rear. The bearing
housing -B- remains fitted to the gearbox housing -C-.
– Secure bearing housing to gearbox housing -arrows- with two

bolts M8 (length approx. 70 mm) and washers.
– Tighten these 2 bolts -arrows- to max. 5 Nm.
– Detach oil collector -A-.

– Check that the 2 gears are still engaged and then unscrew and
remove the multi-point socket head bolt -1- for input shaft.
– Detach 6th speed selector gear with inner race for roller bear‐
ing and thrust washer.
A - Two-arm puller , e.g. -Kukko 20/10-
Caution
Risk of damage to dog teeth on 6th speed selector gear.

• Hooks of two-arm puller must not come into contact with
dog teeth of 6th speed selector gear during removal.
Note
Check the gear teeth on the selector gears and gear wheels for
damage after pulling them off.
– Remove synchro-ring and needle bearing for 6th speed se‐

lector gear.
– Pull off 6th gear wheel.

A - Two-arm puller , e.g. -Kukko 20/10-
– Remove spacer sleeve from output shaft.
– Pull out pin with clip -A- for securing selector fork for 5th and
6th gear from selector rod -B-.
• Mark installation position of locking collar in relation to syn‐
chronising hub -arrow-.
– Move selector fork -C- downwards and detach with locking
collar -D-.

– Heat synchronising hub -arrow- for 5th and 6th gear to approx.
100° C using hot air blower -V.A.G 1416- .
– Pull off 5th speed selector gear together with needle bearing
inner race for 6th gear and synchronising hub for 5th/6th gear.
A - Two-arm puller , e.g. -Kukko 20/10- with 200 mm hooks
Note
♦ Counter-hold two-arm puller using e.g. open end spanner

-B-.
♦ If the needle bearing inner race for 6th gear is in contact with
press tool -VW 433- , insert locking pin -2064- into hole in input
shaft to pull off the components all the way.
– Pull off 4th and 5th gear wheels together.

A - Puller , e.g. -Kukko 18/2-
Note
Counter-hold puller -A- using e.g. gearbox bracket -2004- .
– Pull off 4th speed selector gear with needle bearing inner race
for 5th gear and thrust washer.
Caution
Risk of damage to dog teeth on 4th speed selector gear.

• Hooks of two-arm puller must not come into contact with
dog teeth of with

4threspect
speed selector gear duringin removal.
to the correctness of information this document. Copyright by AUDI AG.

– Counter-hold two-arm puller using e.g. open end spanner
-B-.
– Remove synchro-ring and needle bearing for 4th speed se‐
lector gear.
– If fitted, remove lock washer -A- from selector rod for 3rd and
4th gear, using side-cutting pliers or similar.
– Remove spring -B-.

– Pull pin with clip -A- securing selector fork for 3rd and 4th gear
out from selector rod -B-.
– Detach selector fork -C- with locking collar -D-.
– Remove circlip for 3rd gear and 4th gear synchronising hub
and note thickness of circlip.
– Pull off 3rd speed selector gear with synchronising hub for 3rd
and 4th gear.
A - Puller , e.g. -Kukko 18/2-
Note
Counter-hold puller -A- using e.g. gearbox bracket -2004- to pre‐

vent plate -T40086- from making contact with 3rd gear wheel or
selector rod for 5th and 6th gear.
– Remove circlip for 3rd speed selector gear needle bearing and
detach 3rd gear needle bearing.
– Pull off thrust washer -B- for 3rd speed selector gear.
– Remove circlip for 3rd gear wheel and note thickness of circlip.
– Pull off 3rd gear wheel.

– Unscrew bolts -arrows- for reverse shaft support.

– Unscrew the 2 bolts -A- for bearing housing at gearbox hous‐
ing.
– Remove the bearing housing -B- together with the shafts.
– Insert an internal puller -A- e.g. -Kukko 21/2- into bore for re‐
verse shaft support.
– Spread open internal puller far enough for it to make contact
with reverse shaft support -B-.
– Drive reverse shaft support carefully out of bearing housing
-direction of arrow- and remove with reverse gear wheel.
– Now pull out input shaft -A- carefully from bearing housing at
an angle from the front -direction of arrow-.
– Pull pin with clip -A- for securing selector fork for reverse gear
out from selector rod -B-.
– Detach selector fork -C- with locking collar -D-.

– Press off synchronising hub for reverse gear from output shaft.
Note
Place the bearing housing onto thrust plates -VW 401- and -VW
402- so that the output shaft and selector rods are not damaged
when pressing off the synchronising hub.
– Detach reverse selector gear, needle bearing for reverse se‐

lector gear and reverse gear synchronising hub.
– Guide output shaft out of selector fork for 1st and 2nd gear and
bearing housing.
Assembling gearbox
• If the input shaft or the gearbox housing have been renewed,
you must first re-determine the thickness of the input shaft cir‐
clips ⇒ “1.3 Adjusting input shaft”, page 173 .
Note
♦ Lubricate all needle bearings with gear oil before fitting.

♦ Checking synchro-rings for wear ⇒ page 172 .
♦ Inserting spring in selector gear ⇒ page 172 .
♦ Heat gear wheels, needle bearing inner races and synchro‐
nising hubs to 130 °C (max.) before pressing on (wear pro‐
tective gloves).
– Insert output shaft in bearing housing and selector fork for 1st
and 2nd gear.
– Place reverse gear selector gear with needle bearing, spring
and synchro-ring onto output shaft.
• The lugs on synchro-ring should engage into recesses in se‐
lector gear.
– Press on reverse gear synchronising hub.

• Installation position: high inside collar faces 3rd gear wheel.
– Check axial clearance of reverse selector gear.

– Now insert input shaft -A- with needle roller bearing -B- into
bearing housing in -direction of arrow- at an angle towards the
rear.
– Install reverse gear wheel and tighten 3 bolts -arrows- for re‐
verse shaft support to 30 Nm.
Exploded view - reverse gear wheel ⇒ page 120
– Slide reverse gear selector fork -C- together with locking collar
-D- onto selector rod -B- and reverse gear synchronising hub.
• The markings on locking collar and synchronising hub
-arrow- must coincide.
• The chamfer on the locking collar faces the reverse selector
gear.
– If the bores of selector fork and selector rod coincide, clip in
pin with clip -A-.
– Place plate -T40088/1- on press table and insert the bearing

housing with shafts and selector rods.

– Press on 3rd gear wheel.

• Installation position: machined side faces reverse gear syn‐
chronising hub.
– Insert circlip for 3rd gear wheel.
• When renewing gear wheel or output shaft:
Re-determine thickness of circlip for 3rd gear wheel:
– Determine the thickest circlip that will just fit and install it. For
part number refer to ⇒ Electronic parts catalogue .
The following circlips are available:
Circlip thickness (mm)
1.90 1.98 2.06
1.94 2.02 2.10
– Press on thrust washer -A- for 3rd speed selector gear until
limit stop.
– Fit needle bearing for 3rd speed selector gear -1- and circlip
-2- for 3rd gear needle bearing onto input shaft.
– Then fit 3rd speed selector gear with spring and synchro-ring.
lector gear.
– Press on heated synchronising hub for 3rd and 4th gear

• Installation position: high inside collar faces 3rd speed selector
gear.

– Insert circlip for synchronising hub for 3rd and 4th gear.
• When renewing synchronising hub or input shaft:
Re-determine thickness of circlip for synchronising hub for 3rd
and 4th gear:
1.90 1.96 2.02
1.93 1.99 2.05
– Check axial clearance of 3rd speed selector gear.
– Protected
Slide selector fork
by copyright. for for
Copying 3rd andor 4th
private gearpurposes,
commercial -C- together with
in part or in lock‐
whole, is not
ing collar -D- onto selector rod -B- and synchronising hub
for
3rd and 4th gear.
pin with clip -A-.
Note
Do not insert pin with clip for 5th/6th gear selector fork (∅ 6 mm)
into selector fork for 3rd and 4th gear.
– If previously fitted, install spring -B- on selector rod for 3rd and
4th gear and drive on lock washer -A-.
• Engage 3rd gear before driving on lock washer -A-.
• Installation position of lock washer: collar -arrow 1- faces
spring -B-.
• Lock washer must engage below shoulder -arrow 2- on selec‐
tor rod.
Note
Different versions are fitted - either with or without spring on se‐

lector rod for 3rd and 4th gear.
– Fit 4th speed selector gear -A- with spring, synchro-ring, nee‐
dle bearing and thrust washer for 3rd and 4th gear -B-.
– Press on heated inner race -C- for needle bearing for 5th
speed selector gear.
– Check axial clearance of 4th speed selector gear.

– Heat 4th gear wheel and press on.

• Installation position: high inside collar faces 5th gear wheel.

• Installation position: high inside collar faces 4th gear.
– Place 5th speed selector gear with spring, synchro-ring and

needle bearing onto input shaft.
lector gear.
– Fit and press on heated synchronising hub for 5th and 6th
gear.
– Slide selector fork for 5th and 6th gear -C- together with locking
collar -D- onto synchronising hub for 5th and 6th gear.
– Move selector fork for 5th and 6th gear -C- into selector rod
-B-.
pin with clip -A-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Press on heated inner race for needle bearing for 5th speed
selector gear.
– Fit 6th speed selector gear with spring, synchro-ring, needle

bearing and thrust washer for 6th gear -A-.
– Heat inner race -B- for needle roller bearing and press on.
– Fit spacer sleeve -A- onto output shaft.

– Insert circlip -A- for 6th gear wheel.

• When renewing gear wheel or output shaft:
Re-determine circlip -A- for 6th gear wheel:
1.90 2.02 2.14
1.93 2.05 2.17
1.96Protected by copyright. Copying
2.08for private or commercial purposes,
2.20 in part or in whole, is not
1.99 with respect to the correctness
2.11 of information in this document. Copyright by AUDI AG.
– Take out bearing housing from plate -T40088/1- .

– Secure bearing housing to gearbox housing with two bolts M8

(length approx. 70 mm) -arrows- and washers.
– Tighten these 2 bolts -arrows- to max. 5 Nm.
Note
Do not install oil collector -A- at this stage.
– Move two selector rods -arrow A- and -arrow B- to lock input

shaft by selecting two gears (e.g. reverse gear and 1st gear).
– Tighten multi-point socket head bolt -1- for input shaft to speci‐
fied torque ⇒ Item 40 (page 119) .
– Then remove the complete bearing housing from the gearbox
housing.
– Check if the 2 dowel sleeves are installed between the gear‐
box housing and bearing housing.
– Apply sealing paste -AMV 188 001 02- evenly and not too
thickly onto contact surfaces between gearbox housing and
bearing housing.
– Fit bearing housing onto gearbox housing.
– Clip oil collector -A- into reverse shaft support.
Note
Make sure that the bolts -arrows- are removed.

– Check if the 2 dowel sleeves are installed between the bearing

housing -B- and gearbox cover -A-.
– Apply sealing paste -AMV 188 001 02- evenly and not too
thickly onto contact surfaces between bearing housing and
gearbox cover.
– Insert securing bolts for gearbox cover -A- and bearing hous‐
ing -B- to gearbox housing -C-.
– Tighten bolts -arrows- to specified torque

⇒ Item 18 (page 116) .
– Push assembly sleeve -01E 311 120- -A- onto selector shaft
-B-.
Note
To avoid damaging oil seal -C-, always use assembly sleeve

-01E 311 120- -A- when installing oil seal and selector shaft.
– Move selector rods to neutral.

– Install complete selector shaft.
♦ Installation position: Chamfer of selector shaft points down‐
wards.
taneously inserting pin -3-.
• Installation position for pin by
Protected -3-: The groove
copyright. Copying for-arrow- on pin purposes, in part or in whole, is not
private or commercial
points towards selector shaft
permitted cover.
– Clean threads of locking bolts -1- with a wire brush. Then in‐
stall bolts with locking fluid -AMV 185 101 A1- and tighten to
specified torque ⇒ Item 8 (page 115) .

– Fit cover -A- with new O-ring.

– Clean threads of bolts -arrows- with a wire brush. Then install
bolts with locking fluid -AMV 185 101 A1- and tighten to speci‐
fied torque ⇒ Item 13 (page 115) .
– Fit rear circlip -arrow- for input shaft ball bearing.

– Then push ball bearing onto input shaft.
Installation position:
The closed side of the ball cage faces the gearbox housing.
– Pressing in ball bearing:

First screw door hinge alignment tool (M8 and M10) -3114/2- into
tapped hole for ball-head pin.
Slide the thrust plate -T10246/2- onto input shaft.
Now position fitting tool -T10246/1- behind splines for clutch plate.
Tighten bolts -A- only slightly. The bolts locate in the recesses in
the thrust plate -T10246/2- .
Press in ball bearing onto the stop by tightening the bolts alter‐
nately (1/2 turn at a time).
– Now fit front circlip -D- for input shaft ball bearing.
– Then fit dished spring -C-.

The convex side faces guide sleeve -B-.
– Fit a shrink hose onto input shaft splines.
– Fit guide sleeve -B- for release bearing ⇒ page 30 .
– Remove shrink hose.
– Fit clutch release lever -A- with release bearing ⇒ page 30 .
– Select all gears.

7 Servicing gearbox cover

equipment required
♦ Press tool -VWby408
Protected A- Copying for private or commercial purposes, in part or in whole, is not
copyright.
♦ Press toolwith
-VW 412-
♦ Thrust pad -VW 512-

♦ Tube -VW 519-

♦ Thrust plate -VW 447 i-

♦ Support plate -VW 801-
♦ Guide pin -10 - 15-
1331-
♦ -1- internal puller -Kukko
21/2-
21/5-
21/6-
22/2-
7. Servicing gearbox cover 143

1 - Gearbox cover
❑ Fit sealing plug on new
gearbox cover
❑ Drive in new sealing
plug until flush
⇒ page 146
2 - Dowel sleeve
❑ 2x
❑ For centralising gearbox
cover on bearing hous‐
ing
❑ Drive out and in with drift
-3121-
3 - Roller bearing
❑ Bearing for output shaft
in gearbox cover
❑ Always renew
❑ Pulling out ⇒ page 145
❑ Pressing in
⇒ page 145
4 - Roller bearing
❑ Bearing for input shaft in
gearbox cover
❑ With oil guide
❑ Always renew
❑ Pressing in
⇒ page 146
5 - Ball sleeve
❑ For selector rod for 1st
and 2nd gear
❑ Driving in ⇒ page 145
6 - Ball sleeve
❑ For selector rod for 5th and 6th gear
8 - Retaining plate
❑ Secures needle bearing ⇒ Item 3 (page 144) and needle roller bearing ⇒ Item 4 (page 144) in gearbox
cover
❑ Installation position ⇒ page 146
9 - Sealing plug
❑ Drive in flush ⇒ page 146

Pulling roller bearing for output shaft out of gearbox cover

B - Internal puller 37 ... 46 mm , e.g. -Kukko 21/6-
Note
Always renew roller bearing after pulling out.
Pressing new roller bearing for output shaft into gearbox cover as
far as the stop (press in carefully)

Support gearbox cover with thrust plate -VW 447 i- directly below
bearing mounting.
Pulling out ball sleeve -C- from gearbox cover

B - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-
Driving ball sleeve into gearbox cover until flush

Fit ball sleeve -1- and -2- so that side with lettering (thicker metal)
faces guide pin -10 - 15- or centring mandrel -3176- .
Note
Due to the housing depth use centring mandrel -3176- for driving
in ball sleeve -2-.
7. Servicing gearbox cover 145

Pulling roller bearing for input shaft out of gearbox cover

Shorten (cut off) oil guide in roller bearing in order to insert internal
puller -B-.
Note
Always renew roller bearing after pulling out.

Pressing new roller bearing for input shaft into gearbox cover as
far as the stop (press in carefully)
Support gearbox cover with thrust plate -VW 447 i- directly below
bearing mounting.
Securing needle roller bearing and needle bearing in gearbox

cover.
– Insert retaining plate -2- with the high shoulder -arrow- facing
needle bearing -1- into gearbox cover.
– Tighten bolt -3- to specified torque ⇒ Item 7 (page 144) .
Drive in plug until flush -arrow-
Caution
Depending on the version, a new gearbox cover can be sup‐

plied with or without the sealing plug -arrow-.

8 Servicing bearing housing

equipment required
♦ Press tool -VW 408 A-
♦ Installing sleeve -VW 455-
♦ Tube -VW 516-
8. Servicing bearing housing 147

♦ Guide pin -10 - 15-

♦ Thrust plate -3074-
21/2-
22/1-
♦ Drift -T40085-

1 - Bearing housing
❑ Re-determine shim “S4”
when renewing
⇒ page 221
2 - Outer race
❑ For needle roller bear‐
ing on input shaft
❑ Driving out ⇒ page 150
❑ Pressing in
⇒ page 150
3 - Shim “S4”
❑ Table of adjustments
⇒ page 211
❑ Re-determine when re‐
newing bearing housing
⇒ page 221
4 - Tapered roller bearing outer
race Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For output shaft

5 - Selector rod for 1st and 2nd
gear
❑ Only renew together
with selector fork for 1st
and 2nd gear (secured
together by means of a
pin)
6 - Reverse gear selector rod
7 - Ball sleeve
❑ (Front) for reverse gear
selector rod
❑ Pressing in ⇒ page 151
8 - Ball sleeve
❑ (Rear) for reverse gear selector rod
9 - Selector rod for 3rd and 4th gear
❑ With or without spring-loaded selector fork (depending on version) ⇒ Item 10 (page 117)
10 - Selector rod for 5th and 6th gear
❑ Remove burrs and scoring after removing from bearing housing
11 - Ball sleeve
❑ Pull out with internal puller -Kukko 21/2-
❑ Drive in until flush using guide pin -10 - 15-
12 - Locking bush
❑ For selector rod for 3rd and 4th gear

13 - Locking bush
14 - Ball sleeve
❑ Pull out with internal puller -Kukko 21/2-
Driving outer race for needle roller bearing out of bearing housing
– Clamp bearing housing in vice, using jaw protectors -C-.
– Drive out outer race -A- using drift -B- by alternately applying
drift to the bearing housing recesses located opposite to each
other -arrow-.
Pressing outer race for needle roller bearing into bearing housing
until limit stop
Pulling front ball sleeve out of reverse gear selector rod


Pressing front ball sleeve into reverse gear selector rod until limit
stop.
Fit ball sleeve -arrow- so that side with lettering (thicker metal)
faces guide pin -10 - 15- .
Pulling out rear ball sleeve for reverse gear selector rod
– Clamp actuating arm of selector rod in vice, using jaw protec‐
tors -C-.
– Fit press tool -VW 454- and installing sleeve -VW 455- onto
selector rod.
B - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko
Protected 21/2- Copying for private or commercial purposes, in part or in whole, is not
by copyright.
Pressing in rear ball sleeve -A- for reverse gear selector rod
Driving in ball sleeve for selector rod for 3rd and 4th gear
Fit ball sleeve so that side with lettering (thicker metal) faces guide
pin -10 - 15- .
• Dimension for pressing in -a- = 2.5 mm

Removing and installing locking bush for selector rod

• Remove the relevant selector rod (for 3rd and 4th gear or for
5th and 6th gear).
• Bolt bearing housing -B- with gearbox cover -A- onto gearbox
housing prior to driving out and driving in the locking bushes
-C-.
– Drive out the old locking bush inwards into bearing housing.
– Drive in new locking bush until flush.

9 Servicing gearbox housing

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Tube -VW 423-
♦ Multi-purpose tool -VW
771-
9. Servicing gearbox housing 153

♦ Guide pin -10 - 15-

♦ Installing tool -40 - 503-
1331-
21/2-
22/2-
♦ Drift -T40085-

1 - Gearbox housing
❑ When renewing: adjust
input shaft
⇒ page 173 , adjust out‐
put shaft and differential
(final drive gear set)
⇒ page 211
2 - Oil seal for selector shaft
❑ ⇒ “10.2 Renewing oil
seal for selector shaft
with gearbox removed
(gearbox remains as‐
sembled)”, page 163
❑ ⇒ “10.3 Renewing oil
seal for selector shaft
with gearbox installed”,
page 165
❑ Always use assembly
sleeve to fit oil seal (if
selector shaft remains
installed in gearbox)
⇒ page 163
race (right-side)
❑ For differential
❑ If renewing: adjust dif‐
ferential (crown wheel)
⇒ page 223
4 - Shim “S2”
❑ Note thickness
⇒ page 211
5 - Bush
❑ Secures magnet ⇒ Item 6 (page 155) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Drive in (for example, with press tool -VW 408 toA-
with respect thewhen renewing
correctness gearbox
of information in this document. Copyright by AUDI AG.
6 - Magnet
❑ Clean
7 - Ball-head pin, 25 Nm
❑ Lubricate with grease for clutch plate splines -G 000 100-
8 - Oil drain plug, 45 Nm
9 - Oil seal
❑ For flange shaft (right-side)
❑ Renewing ⇒ “1.2 Renewing oil seal for flange shaft (right-side)”, page 195
10 - Locking bush
❑ For selector rod for 1st and 2nd gear
11 - Locking bush
❑ For reverse gear selector rod

12 - Ball sleeve
❑ For selector rod for 1st and 2nd gear
13 - Ball sleeve
14 - Shim “S3”
❑ Note thickness
❑ Table of adjustments ⇒ page 211
15 - Tapered roller bearing outer race
❑ For output shaft
❑ Removing and installing ⇒ Item 3 (page 177)
16 - Bolt, 24 Nm
❑ Secures needle bearing ⇒ Item 17 (page 156) for input shaft
17 - Needle bearing
❑ For input shaft
❑ Driving out ⇒ page 157
18 - Oil collector
❑ With magnet
❑ Installation position in gearbox housing ⇒ page 158
19 - Ball sleeve
❑ For selector shaft
20 - Cap
❑ For gearbox breather
21 - Breather pipe
❑ Drive in onto stop
❑ Clip in cap for gearbox breather
Pulling out oil seal for selector shaft with gearbox dismantled

Driving in oil seal for selector shaft

– Lightly oil outer circumference of oil seal.
– Drive oil seal -arrow- into housing as far as it will go.
Removing and installing locking bush for selector rod

– Drive out the used locking bush -A- inwards into gearbox
housing.
– Drive in new locking bush into gearbox housing -B- until flush.
Pulling out ball sleeve -C- from gearbox housing.

Driving out input shaft needle bearing from gearbox housing

– Unscrew bolt for securing needle bearing ⇒ page 158 .
– Fit adapter -VW 295 A- with smaller outside diameter into nee‐
dle bearing.
– Drive out needle bearing with drift -VW 295- .

Pressing in input shaft needle bearing until limit stop

– Secure needle bearing after pressing in ⇒ page 158 .
Securing input shaft needle bearing

– Secure input shaft needle bearing with bolt -2-.
– Then insert oil collector -1- into gearbox housing.
Pulling out selector shaft ball sleeve

A - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-
Driving in ball sleeve for selector shaft

Fit ball sleeve so that side with lettering (thicker metal) faces guide
pin -10 - 15- .
– Drive in ball sleeve until flush.

10 Servicing selector shaft

⇒ “10.1 Removing and installing selector shaft with gearbox in‐
stalled”, page 159
⇒ “10.2 Renewing oil seal for selector shaft with gearbox removed
(gearbox remains assembled)”, page 163
⇒ “10.3 Renewing oil seal for selector shaft with gearbox instal‐
led”, page 165
⇒ “10.4 Removing and installing reversing light switch F4 ”, page
167
10.1 Removing and installing selector shaft

with gearbox installed
♦ Tube -VW 423-

♦ Locking fluid -AMV 185 101 A1-
Removing



10. Servicing selector shaft 159

– Unscrew heat shield -arrow- for drive shaft (right side) and, if
fitted, also for drive shaft (left-side).
– Remove front exhaust pipe (right side) ⇒ Rep. Gr. 26 .
Note
-Item 1- can be disregarded.
– Remove nut -arrow- and detach gearbox selector lever from

selector shaft.

F4- .

– Remove bolts -arrows- and take off selector shaft cover -A-.
– Unscrew the two locking bolts -1- for selector shaft.

• Make sure that no gear has been engaged.
taneously removing pin -3-.
– Pull out selector shaft.
– Carefully pry out oil seal with a screwdriver.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Renew oil seals and O-rings.
– Install selector shaft.

• Installation position: Chamfer on selector shaft -B- points
downwards.
Note
Ignore -item A- and -item C-.

taneously inserting pin -3-.
• Installation position: groove -arrow- on pin -3- faces towards
selector shaft cover.
– Clean threads of locking bolts -1- with a wire brush. Then in‐
stall bolts with locking fluid -AMV 185 101 A1- and tighten to
specified torque.
– Fit cover -A- with new O-ring.

– Clean threads of bolts -arrows- with a wire brush. Then install
bolts with locking fluid -AMV 185 101 A1- and tighten to speci‐
fied torque.
Note
Use assembly sleeve -01E 311 120- -item A- to avoid damaging

the oil seal -C- when installing.
– Lightly oil outer circumference of oil seal -arrow-.

– Install front exhaust pipe and align exhaust system so it is free

of stress ⇒ Rep. Gr. 26 .
– Secure heat shield -arrow- for drive shaft (right-side) and, if
fitted, also for drive shaft (left-side) to gearbox.
Tightening torques
Component Nm
Locking bolts for selector shaft 45
Selector shaft cover 24
Connecting rod to gearbox 20
Gearbox selector lever to selector shaft 20
10.2 Renewing oil seal for selector shaft with

gearbox removed (gearbox remains as‐
sembled)
Note
Removal is also possible with gearbox installed in vehicle

⇒ page 165 .

♦ Tube -VW 423-
♦ Extractor tool -T20143/1-
♦ Sealing grease -G 052 128 A1-

Removing
• With selector shaft installed
– Carefully lever out oil seal, taking care not to damage shaft.
• With selector shaft removed

– Carefully lever out oil seal using a screwdriver or oil seal ex‐
tractor lever -VW 681- .
Installing
– To avoid damaging oil seal -C-, always use assembly sleeve
– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease -G 052 128 A1- .

10.3 Renewing oil seal for selector shaft with

gearbox installed
♦ Tube -VW 423-
♦ Extractor tool -T20143/1-

Removing


– Remove heat shield for drive shaft (left-side).
– Disconnect exhaust system at clamp (left-side) -left arrow-.
– Remove front exhaust pipe (left-side) with catalytic converter
⇒ Rep. Gr. 26 .

selector shaft.
– Carefully lever out oil seal, taking care not to damage shaft.
Installing
– To avoid damaging oil seal -C-, always use assembly sleeve

– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease -G 052 128 A1- .

The remaining installation steps are carried out in the reverse se‐
quence; note the following points:
– Install front exhaust pipe with catalytic converter and align ex‐
haust system so it is free of stress ⇒ Rep. Gr. 26 .
– Install heat shield for drive shaft (left-side).
– Check gear oil level in gearbox ⇒ page 110 .
Tightening torques
Component Nm
Gearbox selector lever to selector shaft 20
Heat shield above drive shaft(s) to gearbox 23
10.4 Removing and installing reversing light

switch -F4-
Removing

F4- on gearbox (right-side).

– Unscrew reversing light switch -F4- from selector shaft cover

-arrow-.
Installing
– Screw reversing light switch -F4- into selector shaft cover
-arrow-.
– Attach electrical connector -arrow- for reversing light switch -

F4- on gearbox (right side).
Component Nm
Reversing light switch -F4- 20

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Exploded view - input shaft”, page 169
⇒ “1.2 Dismantling and assembling input shaft”, page 171
⇒ “1.3 Adjusting input shaft”, page 173
1.1 Exploded view - input shaft
Note
♦ Refer to technical data when installing new gears ⇒ page 1 .

♦ Lubricate all bearings on input shaft with gear oil before installing.
♦ The position of the ball bearing ⇒ Item 2 (page 169) will be affected if components ⇒ Item 4 (page 169) or
⇒ Item 7 (page 169) are renewed. In this case the input shaft must be re-adjusted ⇒ page 173 .
1 - Circlip
❑ Mark
❑ Installation position
⇒ page 173 , -item 1-
❑ Determining thickness
shaft”, page 173
2 - Ball bearing
⇒ “6.6 Assembly se‐
quence - dismantling
and assembling gear‐
box”, page 120
3 - Circlip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Mark with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Installation position
⇒ page 173 , -item 2-
❑ Determining thickness
shaft”, page 173
4 - Gearbox housing
5 - Needle bearing
❑ For input shaft
❑ Secured with bolt
6 - Bolt, 24 Nm
❑ Secures needle bearing
⇒ Item 5 (page 169) for
input shaft
7 - Input shaft
❑ Adjusting ⇒ page 173
1. Input shaft 169

8 - Roller bearing
❑ Detaching and fitting ⇒ page 172
❑ Installation position: collar faces splines for 2nd gear
9 - Outer race
❑ For needle roller bearing
11 - Thrust washer
❑ For 3rd speed selector gear
12 - Needle bearing
❑ For 3rd gear
13 - Circlip
❑ Mark
❑ Installation position ⇒ page 173 , -item 3-
14 - 3rd speed selector gear
15 - Spring
❑ Insert in 3rd speed selector gear ⇒ page 172
❑ Allocation to selector gear by
Protected ⇒ copyright.
ElectronicCopyingparts catalogue
for private or commercial purposes, in part or in whole, is not
16 - 3rd gear synchro-ring with respect to the correctness of information in this document. Copyright by AUDI AG.
17 - Synchronising hub for 3rd and 4th gear
❑ Installation position: high inside collar faces 3rd speed selector gear
18 - Circlip
❑ Mark
❑ Re-determining thickness ⇒ page 173
19 - Locking collar for 3rd and 4th gear
20 - Needle bearing
❑ For 4th gear
22 - Spring
❑ Insert in 4th speed selector gear ⇒ page 172
❑ Allocation to selector gear ⇒ Electronic parts catalogue
24 - Thrust washer
❑ For 4th speed and 5th speed selector gears
❑ For 5th gear
26 - Needle bearing
❑ For 5th gear
170 Rep. Gr.35 - Gears, shafts


28 - Spring
30 - Synchronising hub for 5th and 6th gear
31 - Locking collar for 5th and 6th gear
❑ For 6th gear
33 - Needle bearing
❑ For 6th gear
35 - Spring
37 - Thrust washer
❑ For 6th speed selector gear
38 - Inner race
❑ For needle roller bearing ⇒ Item 42 (page 171)
41 - Retaining plate
❑ Secures needle roller bearing ⇒ Item 42 (page 171) in gearbox cover
42 - Roller bearing
❑ Bearing for input shaft in gearbox cover
❑ With oil guide
❑ Always renew
43 - Gearbox cover
1.2 Dismantling and assembling input shaft
Note
Removing and installing 3rd to 6th speed selector gears is de‐

scribed in
box”, page 120 .
1. Input shaft 171


♦ Depth gauge
Detaching needle roller bearing from input shaft and fitting needle
roller bearing onto input shaft
Detaching needle roller bearing:
– Bend open needle roller bearing at separating point
-arrow B- just far enough for it to be detached from input shaft
(do not bend open more than necessary).
Fitting needle roller bearing:
• The shoulder -arrow A- faces towards splines for 2nd gear.
– Bend open needle roller bearing at separating point
-arrow B- just far enough for it to be guided over the input shaft
and onto its seat -arrow C-.
Inserting spring in selector gear

The bent end of the spring -arrow- must be hooked into the hole
in the selector gear.
Checking synchro-ring for wear

– Press synchro-ring -E- into locking collar and measure gap
-a- at positions -A-, -B- and -C- using depth gauge -D-.
– Add the measured values and divide by 3.
• The determined value shouldpermitted
not exceed 0.45 mm.

Installation position of circlips

♦ The circlips -1- and -2- secure the input shaft ball bearing.
Determining thickness ⇒ page 173 .
♦ The circlip -3- secures the needle bearing for 3rd speed se‐
lector gear and the 3rd and 4th gear synchronising hub.
Thickness: 2.00 mm.
♦ The circlip -4- secures the 3rd and 4th gear synchronising hub.
Determining thickness ⇒ page 173 .
Determining thickness of circlip for synchronising hub for 3rd and

4th gear
• Synchronising hub is pressed on as far as stop.
1.90 1.96 2.02
1.93 1.99 2.05
1.3 Adjusting input shaft

Determining circlips for input shaft ball bearing
It is necessary to readjust the input shaft when the:
♦ Gearbox housing
or the
♦ Input shaft
are renewed.
♦ Drift sleeve -30 - 100-
1. Input shaft 173

♦ Door hinge alignment tool (M8 and M10) -3114/2-
♦ Fitting tool -T10246-
♦ Digital depth gauge , e.g. -VAS 6087-
Determining thickness for circlip behind input shaft ball bearing
– Fit a provisional circlip -arrow- in the rear groove on the input
shaft.
– Then push ball bearing onto input shaft.
The closed side of the ball cage faces the gearbox housing.
– Pressing in ball bearing:

First screw pin (M8 and M10) -3114/2- into tapped hole for ball-
head pin.
Slide the thrust plate -T10246/2- onto input shaft.
Now position fitting tool -T10246/1- behind splines for clutch plate.
Tighten bolts -A- only slightly. The bolts locate in the recesses in
the thrust plate -T10246/2- .
Press in ball bearing onto the stop by tightening the bolts alter‐
nately (1/2 turn at a time).

– Then fit dished spring -1-.

The convex side faces guide sleeve -2-.
– Fit a shrink hose onto input shaft splines.
– Bolt guide sleeve to gearbox housing -2- with bolts -3-.
– Then turn the gearbox housing so the joint flange for the bear‐
ing housing points upwards.
• The contact surface must be cleaned to remove sealing paste .
– Place thrust washer -1- for 4th and 5th speed selector gears
onto input shaft.
– Apply digital depth gauge (e.g. -VAS 6087- ) to thrust washer
-1- and measure distance to contact surface of housing. The
measuring point on the housing contact surface must be as
close to the input shaft as possible.
Note
When measuring, lift the input shaft with e.g. support bridge -30
- 211 A- or the help of a 2nd mechanic so that the play in the ball
bearing is taken up.
• Specification: distance “a” = 164.14 mm
Note
♦ If the measured value exceeds the specification, use a thinner

circlip than the circlip installed so that the specification is at‐
tained.
♦ If the measured value is below the specification, use a thicker
circlip than the circlip installed so that the specification is at‐
tained.
♦ Determine the circlip thickness to meet the specification as
exactly as possible (164.14 mm).

1.54 2.08 2.62
1.63 2.17
permitted unless authorised 2.71
by AUDI AG. AUDI AG does not guarantee or accept any liability
1.72 2.26 2.80
1.81 2.35 2.89
1.90 2.44
1.99 2.53
– Select circlip from table. For part number, refer to ⇒ Electronic
parts catalogue .
1. Input shaft 175

Checking adjustment and checking distance “a”:

• Determined circlip is installed.
The distance “a” should be 164.14 mm ± 0.04 mm if the correct
circlip has been selected.
Determining thickness for circlip in front of input shaft ball bearing
– Knock rear circlip (as determined) and ball bearing onto input
shaft using drift sleeve -30 - 100- .
– Determine the thickest circlip which will still just fit.

– Refer to table ⇒ page 175 to determine correct circlip. For part
number, refer to ⇒ Electronic parts catalogue .

2 Pinion shaft (output shaft)

⇒ “2.1 Exploded view - pinion shaft (output shaft)”, page 177
⇒ “2.2 Dismantling and assembling pinion shaft (output shaft)”,
page 180
2.1 Exploded view - pinion shaft (output shaft)
Note
♦ Refer to technical data ⇒ page 1 when installing new gear wheels or the final drive gear set.
♦ Refer to technical data whenby installing
Protected newforgear
copyright. Copying privatewheels
or commercial purposes, in part or in whole, is not
♦ Lubricate all needle bearings onto output
with respect shaftof information
the correctness with gear oildocument.
in this before Copyright
installing.
by AUDI AG.
♦ Adjustment work is required when renewing the parts marked with 1). Table of adjustments ⇒ page 211
1 - Gearbox housing 1)
2 - Shim “S3”
⇒ page 211
race 1)
❑ Pressing in
⇒ page 184 and
⇒ page 185
1)
❑ Is mated with crown

wheel, always renew to‐
gether as a set
❑ Adjusting pinion shaft
and crown wheel
⇒ page 209
5 - Tapered roller bearing inner
race 1)
❑ Will be damaged during
removal
❑ Renew
❑ Pressing off
⇒ page 186
❑ Pressing on
⇒ page 187
6 - Circlip
❑ Re-determine thickness
if tapered roller bearing
is renewed ⇒ page 187
7 - Needle bearing
❑ For 1st gear
2. Pinion shaft (output shaft) 177

8 - 1st speed selector gear

❑ Check axial clearance after installing using feeler gauge ⇒ page 190 (0.20 ... 0.50 mm)
9 - Inner ring for 1st gear
❑ Renew if scored or if there are visible traces of wear
10 - Intermediate ring for 1st gear
11 - Synchro-ring for 1st gear
12 - Locking collar for 1st and 2nd gear
❑ Assembling locking collar/synchronising hub ⇒ page 190
13 - Locking piece
❑ Installing locking pieces (3x) ⇒ page 190
14 - Synchronising hub for 1st and 2nd gear
❑ Installation position: high inside collar faces 2nd speed selector gear
❑ Pressing off ⇒ page 186
❑ Pressing on ⇒ page 189
❑ Assembling locking collar/synchronising hub ⇒ page 190
15 - Circlip
❑ Mark
❑ Re-determine thickness when renewing 1st and 2nd gear synchronising hub or pinion shaft
⇒ page 187
16 - Needle bearing
❑ For 2nd gear
17 - Synchro-ring for 2nd gear
❑ Renew if scored or if there are visible tracespermitted
of wear
18 - Intermediate ring for 2nd gear


19 - Inner ring for 2nd gear
20 - 2nd speed selector gear
❑ Check axial clearance after installing using feeler gauge ⇒ page 191 (0.20 ... 0.50 mm)
21 - Circlip
❑ Mark

22 - Tapered roller bearing inner race 1)

23 - Circlip
❑ Mark
24 - Thrust washer
❑ For reverse selector gear
25 - Tapered roller bearing outer race 1)
26 - Shim “S4”
27 - Bearing housing 1)
28 - Needle bearing
❑ For reverse selector gear
29 - Reverse selector gear
30 - Spring
❑ Insert into reverse selector gear ⇒ page 180
31 - Synchro-ring for reverse gear
32 - Reverse gear synchronising hub
❑ Installation position: high inside collar faces 3rd gear wheel
33 - Reverse gear locking collar
❑ Installation position: taper faces reverse gear synchro-ring
34 - 3rd gear wheel
❑ Installation position: machined side faces reverse gear synchronising hub
35 - Circlip
❑ Mark
❑ Re-determine thickness
with respect when renewing
to the correctness of information3rd
in thisgear wheel,
document. reverse
Copyright by AUDIgear
AG. synchronising hub or pinion shaft
⇒ page 187
36 - 4th gear wheel
❑ Installation position: high inside collar faces 5th gear wheel
37 - 5th gear wheel
❑ Installation position: high inside collar faces 4th gear wheel
38 - Spacer sleeve
39 - 6th gear wheel
❑ Installation position: high inside collar faces spacer sleeve ⇒ Item 38 (page 179)
40 - Circlip
❑ Mark


❑ Re-determine thickness when renewing gear wheels for 4th ... 6th gear, the spacer sleeve or the pinion
shaft ⇒ page 187
41 - Needle bearing
❑ Bearing for pinion shaft in gearbox cover
43 - Retaining plate
❑ Secures needle bearing ⇒ Item 41 (page 180) in gearbox cover
44 - Gearbox cover
Inserting spring in selector gear

The bent end of the spring -arrow- must be hooked into the hole
in the selector gear.
Checking synchro-ring for wear

– Press synchro-ring -E- into locking collar and measure gap
-a- at positions -A-, -B- and -C- using depth gauge -D-.
– Add the measured values and divide by 3.
The determined value should not exceed 0.45 mm.
2.2 Dismantling and assembling pinion

shaft (output shaft)
Note
Removing and installing gear wheels for 3rd to 6th gear and the
reverse selector gear is described in
box”, page 120 .


equipment required
♦ Tube -VW 415 A-

♦ Tube -VW 519-

♦ Press tool -40 - 21-
♦ Press tool -3118-
♦ Slotted nut wrench -3155-

♦ Sleeve -3144-
♦ Assembly tool -3253-
♦ Wheel bearing tube -3345-
♦ Hot air blower -V.A.G 1416-
21/8-
♦ -3- Splitter -Kukko 17/2-
22/2-

♦ Inductive heater -
VAS 6414-
♦ Feeler gauge
Pulling outer race for ta‐
pered roller bearing out
of gearbox housing
– Remove differential
⇒ page 199 .
– Fit thrust piece -2050-
with the large diame‐
ter pointing towards
the outer race.
– Fit threaded spindle
and thrust pad of as‐
sembly tool -3253-
with thrust plate -VW
401- onto gearbox
housing.
The outer race will be
pulled out of the gearbox
housing when the nut is
tightened.
Heating gearbox housing in order to fit tapered roller bearing outer

race
– Heat gearbox housing in area of bearing seat for approx. 15
minutes, to approx. 100°C, with hot air blower -V.A.G 1416- .

Pressing tapered roller bearing outer race into gearbox housing

– Insert outer race only after heating gearbox housing and push
into position under workshop press until heat exchange has
taken place.
Pulling tapered roller bearing outer race out of bearing housing

Pressing tapered roller bearing outer race into bearing housing

Support bearing housing with sleeve -3144- directly below bear‐
ing mounting.
– Press in outer race until limit stop.
Pressing off thrust washer for reverse selector gear

A - Splitter 22...115 mm , e.g. -Kukko 17/2-
Note
Fit splitter -A- below thrust washer, and not below circlip.
– Then detach circlip below thrust washer.


Pressing off tapered roller bearing inner race with 2nd speed se‐
lector gear
A - Splitter 22...115 mm , e.g. -Kukko 17/2-
Caution
When pressing off, make sure that only the gear teeth (driving
teeth) of the selector gear and not the dog teeth contact the
splitter -A-. Otherwise the dog teeth will be damaged.
– Remove circlip for tapered roller bearing inner race.
Pressing off 1st and 2nd gear synchronising hub

– Remove circlip before pressing off.
– Press off synchronising hub with 1st speed selector gear.
Pressing off tapered roller bearing inner race

– Remove circlip before pressing off.
– The outer race of the tapered roller bearing -arrow- must be
fitted prior to pressing off the inner race.

Pressing on tapered roller bearing inner race

– Heat inner race to approx. 100 °C and press on.
– Determine thickness of required circlip ⇒ page 187 and install
circlip.
Determining thickness of circlip

Note
The thickness of the circlips for the synchronising hubs and indi‐
vidual gear wheels must also be determined as shown for the
tapered roller bearing.
Overview for installation position of circlips ⇒ page 188

Installation position of circlips

The required circlips for the inner races of the tapered roller bear‐
ings, the synchronising hubs and individual gear wheels should
be selected as shown in ⇒ page 187 .
♦ Circlip -1- secures the tapered roller bearing inner race.
2.50 2.56 2.62
2.53 2.59 2.65
♦ Circlip -2- secures the 1st and 2nd gear synchronising hub.
Identification: blueauthorised
colour by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08
1.99 2.11
♦ Circlip -3- secures the tapered roller bearing inner race.
3.50
♦ Circlip -4- secures thrust washer for reverse selector gear.
3.50
♦ Circlip -5- secures the 3rd gear wheel.
1.90 1.98 2.06
1.94 2.02 2.10
♦ Circlip -6- secures the 6th gear wheel.
1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08 2.20
1.99 2.11
– Determine circlips according to table. For part number, refer
to ⇒ Electronic parts catalogue .

Installation position of synchro-rings for 1st and 2nd gear
Note
If components are not being renewed, make sure they are re-
installed on the same gear.
– Fit inner ring -2- onto selector gear -1-.

– Fit intermediate ring -3-. Lug -B- must be inserted into recess
-A-.
– Synchro-ring -4- fitted. Guide lugs -C- through recess
-arrow-.
Checking 1st gear inner ring for wear

– Check outer contact surface -arrow- for scoring or visible
traces of wear and renew if necessary.
– Press inner ring onto chamfer on selector gear and measure
gap -a- using a feeler gauge .
Gap -a- As-new installation Wear limit
value
Inner ring for 1st 1.2 ... 2.0 mm 0.6 mm
gear
Checking 1st and 2nd gear intermediate ring for wear

– Check inner friction surface of synchro-ring for scoring or visi‐
ble traces of wear and renew if necessary.
– Press inner ring, intermediate ring and synchro-ring onto
chamfer on selector gear and measure gap -a- using a feeler
gauge .
Gap -a- As-new installation Wear limit
value
1st and 2nd gear 1.4 ... 2.0 mm 0.8 mm
Pressing on 1st and 2nd gear synchronising hub

♦ Installation position:
Higher inside collar faces 2nd gear.
• The lugs of 1st gear synchro-ring and recesses on synchro‐
nising hub must align -arrow- when pressing on.

Assembling 1st and 2nd gear locking collar/synchronising hub

– Fit locking pieces -arrows A- into mounted synchronising hub
-1-.
– Fit locking collar -2- onto synchronising hub so that the wide
teeth of locking collar and synchronising hub -arrow B- coin‐
cide.
– Install circlip for 1st and 2nd gear synchronising hub.
– Install 2nd speed selector gear with needle bearing and syn‐
chro-rings.
Pressing on tapered roller bearing inner race

– Fit circlip for tapered roller bearing inner race onto pinion shaft.
• Shoulder of tube -VW 415 A- faces inner race -arrow-.
Then check axial play of 1st speed and 2nd speed selector gearsauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
⇒ page 190 and ⇒ page 191 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Checking axial play of 1st speed selector gear

– Press 1st speed selector gear -2- in direction of -arrow A- as
far as the stop.
– Measure the distance between the 1st speed selector gear
-2- and synchro-ring -3- using a feeler gauge -1-.
Example: 2.55 mm
– Now press 1st speed selector gear -2- in direction of 2nd
speed selector gear -4-.
– Measure the distance again between the 1st speed selector
gear -2- and synchro-ring -3- using a feeler gauge -1-.
Example: 2.15 mm
• The difference between the two measured values must be be‐
tween 0.20 ... 0.50 mm.

Checking axial play of 2nd speed selector gear

– Check axial play between 2nd speed selector gear -2- and in‐
ner race of tapered roller bearing -3- using a feeler gauge
-1-.
• The play must be 0.20 ... 0.50 mm.
Pressing on thrust washer for reverse selector gear

– Fit circlip -B- onto pinion shaft.
– Press on thrust washer -A- until it makes contact with circlip.

39 – Final drive - differential

1 Renewing oil seals for flange shafts
⇒ “1.1 Renewing oil seal for flange shaft (left-side)”, page 192
⇒ “1.2 Renewing oil seal for flange shaft (right-side)”, page 195
1.1 Renewing oil seal for flange shaft (left-

side)
♦ Drift -VW 295-
♦ Puller -T10037-
♦ Thrust piece -T10387-

♦ Drip tray
Procedure
• Gearbox is installed
Observe general repair instructions ⇒ page 6 .
192 Rep. Gr.39 - Final drive - differential

– Remove front left wheel.

– If fitted, remove noise insulation -arrows- in wheel housing

(left-side).
– If fitted, remove heat shield -arrows- for drive shaft (left-side).

– Detach drive shaft -1- from flange shaft and tie as far as pos‐
sible to front, taking care not to damage surface protection.
– Place drip tray in position.
– Remove flange shaft (left-side); to do so, secure puller -

T10037- to cover for final drive -arrow-.
1. Renewing oil seals for flange shafts 193

– Lever out flange shaft oil seal using a suitable lever.
– Lightly oil outer circumference of new oil seal.

– Drive in new flange shaft oil seal using thrust piece -T10387-
until thrust piece reaches stop; keep seal straight when instal‐
ling.
Note
♦ Driving-in depth (standard): 5.5 mm beneath surface of cover

♦ When carrying out a repair, the oil seal is driven in to a depth
of 6.5 mm using thrust piece -T10387- , so that the new seal
does not bear on the same contact surface on the used flange
shaft.
Note
♦ Inspect for visible signs of damage to polygon bearings -2-

(such as cracking in outer race).
♦ If the polygon bearings -2- do not run smoothly with the flange
shaft removed, this does not necessarily indicate that the
bearings are defective. A test for noisy bearings can only be
performed with the bearings installed.
♦ The polygon bearings can only be renewed together with the
flange shaft.
♦ Always renew circlip for flange shaft -5-.

– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.
– Knock flange shaft in with drift -VW 295- .
– Attach drive shaft to flange shaft ⇒ Rep. Gr. 40 .
– If applicable, bolt on heat shield for drive shaft (left-side).
– Fill up oil in gearbox and check oil level ⇒ page 110 .
– Install noise insulation.
Tightening torque
Component Nm
Heat shield above drive shaft to gearbox 23
1.2 Renewing oil seal for flange shaft (right-

side)
♦ Drift -VW 295-
♦ Puller -T10037-

♦ Thrust piece -T10387-

♦ Drip tray
Procedure
• Gearbox is installed
Observe general repair instructions ⇒ page 6 .
– Loosen bolt for right-side drive shaft / wheel hub.
– Remove front right wheel.
– If fitted, remove noise insulation -arrows- in wheel housing

(right-side).

– Remove heat shield -arrows- for drive shaft (right-side).

– Remove drive shaft (right-side) ⇒ Rep. Gr. 40 .
– Place drip tray in position.

– Remove flange shaft (right-side); to do so, secure puller -
T10037- to gearbox housing -arrow-.
– Lever out flange shaft oil seal -arrow- using a suitable
with respect lever.of information in this document. Copyright by AUDI AG.
to the correctness
– Lightly oil outer circumference of new oil seal.

– Drive in new flange shaft oil seal using thrust piece -T10387-
until thrust piece reaches stop; keep seal straight when instal‐
ling.
Note
♦ Driving-in depth (standard): 5.5 mm beneath surface of cover

♦ When carrying out a repair, the oil seal is driven in to a depth
of 6.5 mm using thrust piece -T10387- , so that the new seal
does not bear on the same contact surface on the used flange
shaft.

Note
♦ Inspect for visible signs of damage to polygon bearings -2-

(such as cracking in outer race).
♦ If the polygon bearings -2- do not run smoothly with the flange
shaft removed, this does not necessarily indicate that the
bearings are defective. A test for noisy bearings can only be
performed with the bearings installed.
♦ The polygon bearings can only be renewed together with the
flange shaft.
♦ Always renew circlip for flange shaft -5-.
– Clamp flange shaft in vice, using jaw covers. Use new circlip
-A- to press old circlip out of groove in flange shaft.
– Knock flange shaft in with drift -VW 295- .
Assembly is carried out in the reverse order to removal; note the
following:
– Install drive shaft ⇒ Rep. Gr. 40 .
– Bolt on heat shield for drive shaft (right-side).
– Fill up oil in gearbox and check oil level ⇒ page 110 .
– Install noise insulation.
Tightening torque
Component Nm
Heat shield above drive shaft to gearbox 23

2 Differential
⇒ “2.1 Removing and installing differential”, page 199
⇒ “2.2 Dismantling and assembling differential”, page 202
2.1 Removing and installing differential

equipment required
♦ Multi-purpose tool -
VW 771-
♦ Socket (27 mm) -3257-
♦ Torque wrench -
V.A.G 1331-
21/5-
2. Differential 199
Note
♦ Removing and installing is possible with the gearbox installed.

♦ The differential can be removed and installed without removing the selector mechanism, input shaft, pinion
shaft and bearing housing. These components must be removed if the differential needs to be adjusted.
♦ Inspect polygon bearings for visible damage.
♦ The polygon bearings can only be renewed together with the flange shaft.
♦ If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate
that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.
♦ A spacer ring is fitted between the polygon bearing and the differential sun wheel on flange shafts with 30
mm spline diameter ⇒ page 201 , -item 4-.
1 - Gearbox housing 1) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Oil seal
❑ Renewing for flange
shaft (left-side)
⇒ page 192
❑ Renewing for flange
shaft (right-side)
⇒ page 195
3 - Circlip
❑ Renew
⇒ page 198
4 - Spacer ring
❑ Is only fitted on flange
shafts with a spline di‐
ameter of 30 mm
❑ Remove with Internal
puller 30 ...37 mm , e.g.
-Kukko 21/5-
❑ Installing ⇒ page 201
5 - Flange shaft
❑ Removing (left-side)
⇒ page 201
❑ Removing (right-side)
⇒ page 201
❑ Drive in with drift -
VW 295- .
❑ Flange shaft assembly
⇒ page 201
6 - Differential with crown
wheel 1)
❑ Dismantling and assem‐
bling ⇒ page 202
7 - O-ring
❑ Always renew
❑ Lubricate with gear oil

8 - Cover for final drive 1)

9 - Bolt, 20 Nm + 90° further
Removing flange shaft (left-side)

– Remove flange shaft (left-side); to do so, secure puller -
T10037- to cover for final drive -arrow-.
Removing flange shaft (right-side)

– Remove flange shaft (right-side); to do so, secure puller -
T10037- to gearbox housing -arrow-.
Installing spacer ring

– Drive new spacer ring in onto stop, taking care to keep ring
straight.
Flange shaft assembly

1- Flange shaft
2- Needle bearing (polygon bearing)
3- Spacer ring
4- Spacer ring - fitted additionally on shafts with 30 mm spline
diameter
5- Circlip
Note
The needle bearings (polygon bearings) do not turn easily when

the flange shaft is removed. This does not indicate that a bearing
is defective.
2. Differential 201
2.2 Dismantling and assembling differential

equipment required
♦ Thrust plate -VW 447 H-
♦ Thrust plate -VW 447 i-

♦ Drift -VW 295-

♦ Thrust pieces for pinion
shaft bearing -VW 470-
♦ Tube -30 - 14-
♦ Tube -3296-
2. Differential 203

1332-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
21/8-
♦ -4- Counter-support -Kukkopermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
22/2- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Inductive heater -VAS 6414-
♦ Feeler gauge
Removing and installing differential ⇒ page 199
Note
♦ Always renew both tapered roller bearings together.


1 - Gearbox housing 1)
2 - Shim “S2”
❑ Note thickness
⇒ page 211
3 - Outer race for tapered roller
bearing (right-side) 1)
4 - Inner race for tapered roller
bearing (right-side) 1)
❑ Pulling off ⇒ page 206
❑ Pressing on
⇒ page 207
5 - Crown wheel1)
❑ Is paired with pinion
shaft (final drive gear
set)
❑ Select correct version
according to gearbox
code letters ⇒ Electron‐
ic parts catalogue
❑ Drive crown wheel off
differential cage using a
punch ⇒ page 208
❑ Fitting on differential
cage ⇒ page 208
6 - Differential cage1) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Bolt, 60 Nm + turn 45° fur‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ther
❑ Renew
❑ Tighten bolts in stages and in diagonal sequence until crown wheel makes full contact with differential
cage. Then tighten to specified torque
8 - Inner race for tapered roller bearing (left-side) 1)
❑ Pulling off ⇒ page 207
9 - Outer race for tapered roller bearing (left-side) 1)
10 - Shim “S1”
❑ Note thickness
11 - Cover for final drive 1)
❑ With O-ring
12 - One-piece thrust washer
❑ Lubricate with gear oil before installing
13 - Sun wheel
14 - Differential pinion pin
❑ Drive out with drift after removing spring pin
2. Differential 205
15 - Spring pin
❑ Secures differential pinion pin
❑ Drive out of differential cage with drift
❑ Press in until 1.5 mm above differential cage
16 - Planet pinion
Pulling tapered roller bearing outer race (right-side) out of gear‐

box housing
– After removing, check shim for damage.
Driving outer race for tapered roller bearing (right-side) into gear‐
box housing
Pulling off inner race for tapered roller bearing (right-side)

– Before setting up puller, place thrust pad -VW 447 H- on dif‐
ferential cage.

Pressing on tapered roller bearing inner race (left and right)
Note
Use the same tools for pressing on tapered roller bearing inner
race on left side and right side.
WARNING
Wear protective gloves.
– Heat inner race to approx. 100 °C, fit in position and press
home.
Pulling off inner race for tapered roller bearing (left-side)

– Before setting up puller, place thrust pad -VW 447 H- on dif‐
ferential cage.
Pulling tapered roller bearing outer race (left-side) out of cover for
final drive
– After removing, check shim for damage.
2. Differential 207
Pressing tapered roller bearing outer race (left-side) into cover for
final drive.
Driving crown wheel off cage
Heating crown wheel to approx. 100 °C and installing

– When fitting crown wheel, use centralising pins -A- (shop-
made tool) to locate.
WARNING
Wear protective gloves.
– Allow to cool slightly before screwing in new securing bolts.

– Then tighten bolts in stages and in diagonal sequence until
crown wheel makes full contact with differential cage.
– Then tighten bolts to specified torque ⇒ Item 7 (page 205) .
Installing bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install sun wheels.
– Insert planet pinions (180° apart) and pivot into position
-arrow-.
– Drive differential pinion pin into final position and secure.

3 Adjusting pinion shaft and crown

wheel
Note
♦ Careful adjustment of the crown wheel and pinion shaft is es‐

sential to ensure that the final drive gives long service and runs
silently. For this reason, the pinion shaft and crown wheel are
matched together during manufacture, and checked to ensure
a good mesh pattern and quiet running in both directions of
rotation. The position of quietest running is found by moving
the pinion shaft in an axial direction and at the same time lifting
the crown wheel out of the zero-play mesh position by the
amount necessary to maintain the backlash within the speci‐
fied tolerance.
♦ The object of the adjustment is to reproduce the setting for
quietest possible running, as obtained on the test machine in
production.
♦ The allowance “r” in relation to the master gauge “Ro” is meas‐
ured for the final drive gear sets supplied as replacement parts
and marked on the outer circumference of the crown wheel.
The final drive gear set (pinion shaft and crown wheel) may
only be renewed together as a matched pair.
♦ Observe the general repair instructions for tapered roller bear‐
ings and shims ⇒ page 6 .
3.1 Adjustment and marking of final drive gear set
3. Adjusting pinion shaft and crown wheel 209

1 - “43185” number of matched

pair of gears
2 - Allowance “r” is based on
the master gauge used on the
test machine in production.
The allowance “r” is always
given in 1/100 mm. For exam‐
ple: “29” indicates r = 0.29 mm
Ro - Length of master gauge
used on test machine
Ro - Crown wheel ∅ 188 mm =
59.65 mm
R - Actual distance between
centre axis of crown wheel and
face of pinion shaft in position
of quietest running for this gear
set
Vo - Hypoid offset

3.2 Position of shims
Note
Table of adjustments when renewing individual components of gearbox ⇒ page 211 .
S1 - Shim for crown wheel in

cover for final drive
S2 - Shim for crown wheel in
gearbox housing
S3 - Shim for pinion shaft in
gearbox housing
S4 - Shim for pinion shaft in
bearing housing
3.3 Table of adjustments
Note
If repairs have been carried out to the gearbox, it is only necessary

to adjust the pinion shaft, crown wheel or final drive set if com‐
ponents have been renewed which have a direct effect on the
adjustment of the final drive. Refer to the following table to avoid
unnecessary adjustment work:
Components
permittedrequiring adjustment:
unless authorised by AUDI AG. AUDI AG Crown
does notwheel Pinion
guarantee or accept shaft
any liability Pinion shaft Backlash
(“S1” + “S2”) (“S3” + “S4”) via Shim “S4” only 0.12 - 0.28
allowance “r”
⇒ page 223 ⇒ page 212 ⇒ page 221 ⇒ page 227

Component renewed
Gearbox housing 1) X X X
Bearing housing X X
Differential cage X X
Tapered roller bearings for pinion X X
shaft
Tapered roller bearings for differential X X
Final drive gear set 2) X X X
Cover for final drive X X
1) If the gearbox housing is renewed the input shaft mustProtected
also be adjusted
by copyright. ⇒ page
Copying 173
for private .
or commercial purposes, in part or in whole, is not
2) Pinion shaft and crown wheel; if necessary, pinion shaft permitted
and crown wheel must always be renewed together.
3.4 Recommended sequence for adjusting

gear set
The following work sequence is recommended to save time when
the crown wheel and pinion shaft have to be adjusted:
♦ Determine total shim thickness “Stotal” (S3 plus S4) for the
specified preload on pinion shaft tapered roller bearings.
♦ Distribute total shim thickness “Stotal” (S3 plus S4) so that
distance from centre of crown wheel to end face of pinion shaft
corresponds to installation dimension “R” determined during
production.
♦ Determine total shim thickness “Stotal” (S1 plus S2) to obtain
specified preload on differential tapered roller bearings.
♦ Distribute total shim thickness “Stotal” (S1 plus S2) so that the
specified backlash between crown wheel and pinion shaft is
obtained.
3.5 Adjusting pinion shaft

Repairs after which the pinion shaft must be adjusted
⇒ page 211 .


equipment required
♦ Transmission removal lev‐
er -VW 296-
♦ Gearbox support -VW 353-
♦ Universal measuring tool -
VW 385-
♦ Universal dial gauge brack‐
et -VW 387-


♦ Assembly device -VW 792-
♦ Sleeve -3144-
♦ Wheel bearing tube -3345-
♦ Dial gauge
♦ Dial gauge extension, 30 mm
Determining total shim thickness “Stotal” for shims “S3” plus
“S4”
(Setting preload of tapered roller bearings for pinion shaft)
• Differential removed

– Press tapered roller bearing outer race for pinion shaft into
gearbox housing without shims.
– Press in tapered roller bearing outer race for pinion shaft with
shim “S4*” (thickness 1.01 mm) into bearing housing.
Note
For measurement purposes a shim “S4” with a thickness of 1.01

mm is inserted provisionally. This is referred to in the following as
“S4*”. “S4*” is exchanged with the final shim “S4” after determin‐
ing measured value “e”.
– Secure gearbox housing onto gearbox support -VW 353- with

bolts -arrows-.
– Press tapered roller bearing inner race -1- onto pinion shaft
and secure ⇒ page 187 .
– Fit selector gears and locking collar for 1st and 2nd gears -2-
⇒ page 180 .
– Press tapered roller bearing inner race -3- onto pinion shaft
⇒ page 190 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert completely assembled pinion shaft in gearbox housing.
– Fit bearing housing and gearbox cover with the 4 dowel
sleeves and tighten bolts to 35 Nm.
– Turn gearbox so that the gearbox cover points downwards.

– Press down on face of pinion shaft with transmission removal

lever -VW 296- until the tapered bearing outer race contacts
the bearing housing.
– Maintain pressure and rotate pinion shaft 5 turns in both di‐
rections to seat tapered roller bearing.
– Fit dial gauge (3 mm measuring range) with 30 mm dial gauge

extension to gearbox housing.
– Preload dial gauge to 1 mm and set to “0”.
The dial gauge extension must contact the machined surface on
the face of the pinion.

– Turn gearbox so that the gearbox cover points upwards.

– Rotate pinion shaft 5 turns in each direction so that the tapered
roller bearing seats properly. Otherwise the result of the meas‐
urement will be incorrect.
– Read off play on dial gauge and note reading.
♦ Measurement in example: 0.46 mm
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the measuring procedure needs to be repeated, the pinion shaft
must first be rotated 5 turns in each direction again so that the
tapered roller bearing seats properly. Preload dial gauge to 1 mm
and set to “0” again.
Formula: “Stotal” = “S4*” + measured value + bearing preload
Example:
Inserted shim “S4*” 1.01 mm
+ Measured value (example) 0.46 mm
+ Bearing preload (constant value) 0.12 mm
= Total shim thickness “Stotal” for “S3” plus 1.59 mm
“S4”
Determining thickness of shim “S3*”

Formula: “S3*” = “Stotal” – “S4*”
Example:
Total shim thickness “Stotal” for “S3” plus “S4” 1.59 mm
– Inserted shim “S4*” 1.01 mm
= Thickness of shim “S3*” 0.58 mm
– Remove tapered roller bearing outer race from gearbox hous‐

ing ⇒ page 184 .
– Fit shim “S3*” in gearbox housing and install outer race again
⇒ Item 3 (page 177) .
– Insert completely assembled pinion shaft into gearbox housing
again.
– Fit bearing housing and gearbox cover with the 4 dowel
sleeves and tighten bolts to 35 Nm.
– Turn pinion shaft 5 turns in each direction so that tapered roller
bearings seat properly.

– Fit assembly device -VW 792- on gearbox housing; when do‐

ing so, insert an M12 nut -A- between assembly device -VW
792- and gearbox housing.
– Fit universal dial gauge bracket -VW 387- with dial gauge and
30 mm extension.
Note
Apply dial gauge extension exactly at centre of intersection of ribs

on gearbox cover -arrow-.
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐

load.
– Loosen gearbox cover bolts and turn pinion shaft several
times.
– If the correct shims have been selected the dial gauge will now
indicate the following value:
♦ 0.06 ... 0.12 mm
– Tighten gearbox cover bolts again to 35 Nm.
– Take down measuring tools.
Determining dimension “e”
Note
Measurement “e” is required to determine the final shim thickness

of “S3” and “S4”.
– Set adjustment rings of universal measuring tool -VW 385/1-

to the following settings:
♦ Dimension -a- = 45 mm
♦ Dimension -b- = 75 mm
– Assemble universal measuring tool -VW 385/1- as illustrated:

♦ Dial gauge extension -VW 385/15- , 9.3 mm long
♦ Master gauge -VW 385/30-
– Set master gauge -VW 385/30- to Ro = 59.65 mm and fit onto
measuring tool.
load.

– Place end measuring plate -VW 385/33- on face of pinion gear.
Note
Ensure contact surface of end measuring plate fits exactly and is

free of oil.
– Remove master gauge and insert measuring tool into housing.

♦ The dial gauge faces towards the final drive cover
– Fit cover for final drive and tighten 4 bolts to 20 Nm.
– Using the adjustable ring, pull 2nd centring disc -VW 385/36-
out as far as possible so that the measuring tool can still just
be turned by hand.

– Turn measuring tool until tip of dial gauge touches end meas‐
uring plate on face of pinion gear and gauge indicates maxi‐
mum deflection (return point).
♦ Measurement in following example: “e” = 0.17 mm (in red
scale)
Note
Then (after removing universal measuring tool), check once again

that the dial gauge indicates “0” with 2 mm preload when master
gauge -VW 385/30- is in place.
Determining thickness of shim “S3”

♦ The allowance “r” in relation to the master gauge “Ro” is meas‐
ured for the final drive gear sets supplied as replacement parts
and marked on the outer circumference of the crown wheel.
♦ Subtract value “e” if measurement is obtained on red scale.
♦ Add value “e” if measurement is obtained on black scale.
Formula:
“S3” = “S3*” + “r”permitted
+ “e” unless
(“e” on blackbyscale)
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
“S3” = “S3*” + “r” – “e” (“e” on red scale)
Example:
+ Allowance “r” 0.29 mm
– Determined value “e” (in red scale) 0.17 mm
= Thickness of shim “S3” 0.70 mm
– Determine shim(s) according to table. For part number, refer

Available shims for “S3”
Shim thickness (mm) 1)

0.53 0.85 1.17
0.57 0.89 1.21
0.61 0.93 1.25
0.65 0.97 1.29
0.69 1.01 1.33
0.73 1.05 1.37
0.77 1.09 1.41
0.81 1.13
1)The exact shim thickness required can be obtained by using
the shim tolerance variations. Install two shims if necessary.
Formula: “S4” = “Stotal” – “S3”

Example:
Total shim thickness “Stotal” for “S3” plus “S4” 1.59
mm
– Thickness of shim “S3” 0.70
mm
= Thickness of shim “S4” 0.89
mm
Shims available for “S4”

0.33 0.73 1.13
0.37 0.77 1.17
0.41 0.81 1.21
0.45 0.85 1.25
0.49 0.89 1.29
0.53 0.93 1.33
0.57 0.91by copyright. Copying for private
Protected 1.37 or commercial purposes, in part or in whole, is not
0.61 with respect to the correctness of 1.41
1.01 information in this document. Copyright by AUDI AG.
0.65 1.05 1.45
0.69 1.09 1.49
Checking adjustment
Checking allowance (tolerance) “r”
– Install pinion shaft with appropriate measured shims “S3” and
“S4”.
– Insert universal measuring tool and perform check measure‐

ment.
– Read off dial gauge anti-clockwise (red scale).
♦ If the shims have been correctly selected, the allowance
“r” (marked on outer circumference of crown wheel) should be
indicated within a tolerance of ± 0.04 mm.
3.6 Re-determining shim “S4” when renew‐

ing bearing housing

♦ Universal dial gauge bracket -VW 387-
♦ Assembly device -VW 792-
♦ Ruler -T40100-
♦ Digital depth gauge , e.g. -VAS 6087-
♦ Dial gauge
♦ Dial gauge extension, 30 mm
– Clean housing flanges.

– Place straightedge (e.g. -T40100- , 39.70 mm wide) -1- on

housing flange.
– Measure difference between depth -a- on old and new bearing
housing with a digital depth gauge (e.g. -VAS 6087- ).
Example:
Depth -a- of previous bearing housing (with 46.50 mm
straightedge width)
Depth -a- of new bearing housing (with 46.65 mm
straightedge width)
= Difference 0.15 mm
– If new bearing housing is deeper, install a thicker “S4” shim.
– If previous bearing housing is deeper, install a thinner “S4”
shim.
Example:
Previous shim “S4” 0.95 mm
+ Difference 0.15 mm
= New shim “S4” 1.10 mm
Shims available ⇒ page 221 .

– Press tapered roller bearing outer race with shim “S4” into
bearing housing ⇒ page 185 .
– Insert completely assembled pinion shaft into gearbox housing
again.
– Fit bearing housing and gearbox cover and tighten bolts to
35 Nm.
– Fit assembly device -VW 792- on gearbox housing; when do‐

ing so, insert an M12 nut -A- between assembly device -VW
792- and gearbox housing.
– Fit universal dial gauge bracket -VW 387- with dial gauge and
30 mm extension.
Note
Apply dial gauge extension exactly at centre of intersection of ribs

on gearbox cover -arrow-.

load. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Loosen gearbox cover bolts and turn pinion shaft
with several
times.
– If the correct shims have been selected the dial gauge will now
indicate the following value:
♦ 0.06 ... 0.12 mm
If this reading is not obtained, the adjustment must be corrected.
3.7 Adjusting crown wheel

(Adjusting differential)


equipment required
♦ Drift -VW 295-
♦ Dial gauge extension -
VW 382/10-
♦ End measuring plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Adjustable measuring lever
-VW 388-


♦ Crown wheel adjusting tool
-VW 521-
♦ Tube -30 - 14-
♦ Torque wrench -
V.A.G 1331-
♦ Dial gauge
♦ Dial gauge extension, 30
mm
It is necessary to readjust the crown wheel when the following

components have been renewed:
Gearbox housing, cover for final drive, tapered roller bearings for
differential, differential cage or final drive gear set
Table of adjustments ⇒ page 211
Determining total shim thickness “Stotal” for shims “S1” plus
“S2”
(Setting preload of tapered roller bearings for differential)
• Pinion shaft removed
– Remove flange shaft oil seals.
– Remove tapered roller bearing outer races for differential and
take out shims ⇒ page 202 .

– Drive outer race for tapered roller bearing (right-side) with

shim “S2” into gearbox housing. For measurement purposes
use a 1.30 mm thick “S2*” shim (or 2 shims of 0.65 mm).
Note
For measurement purposes a 1.30 mm thick shim “S2” is inserted

provisionally. This is referred to in the following as “S2*”. “S2*” is
exchanged with the final shim “S2” after determining backlash.
– Press outer race for tapered roller bearing (left-side) without

shim “S1” into cover for final drive.
– Install differential in gearbox housing. The crown wheel is
positioned on the left-hand side (same side as cover for final
drive).
– Fit cover for final drive with 4 bolts (20 Nm).
– Turn gearbox so that cover for final drive points upwards.
– Turn differential 5 turns in both directions so that the tapered
roller bearings settle.
– Place measuring plate -VW 385/17- on differential.
– Set up measuring tool using 30 mm extension.

– Set dial gauge (3 mm measuring range) -A- to “0” with 2 mm
preload.
Note
The tip of the dial gauge must be applied to the centre of the dif‐
ferential.
– Raise differential without turning, read clearance off dial gauge

and note down.
• Measurement in following example: 0.62 mm

Note
♦ To lift differential, secure crown wheel adjusting tool -

VW 521/4- and -VW 521/12- on right side of differential (hous‐
ing side).
♦ If the measurement has to be repeated, the differential must
again first be turned 5 turns in each direction to settle the ta‐
pered roller bearings.
Formula: “Stotal” = “S2*” + measured value + bearing preload
Example:
Inserted shim(s) “S2*” 1.30 mm
+ Measured value 0.62 mm
+ Bearing preload (constant value) 0.25 mm
= Total shim thickness “Stotal” for “S1” plus 2.17 mm
“S2”
Determining thickness of shim “S1*”
Note
♦ Provisional shim “S1*” is replaced with final shim “S1” after

determining backlash.
♦ Total shim thickness “Stotal” remains unchanged.
Formula: “S1*” = “Stotal” – “S2*”
Example:
– Inserted shim(s) “S2*” 1.30 mm
Protected=byThickness of shim
copyright. Copying “Sor1*”
for private commercial purposes, in part or in whole, 0.87
is not mm
Select
with respect correct shimsof information
to the correctness from ⇒ inElectronic
this document.parts
Copyrightcatalogue
by AUDI AG. .
Measuring backlash
• Pinion shaft fitted with shims “S3” and “S4”.
– Install differential with crown wheel: S1 is fitted on cover side,
S2 in gearbox housing.
– Fit cover for final drive and tighten bolts to 20 Nm.
– Insert crown wheel adjusting tool -VW 521/4- and -
VW 521/12- .
– Turn differential 5 turns in both directions to settle tapered roll‐
er bearings.

– Secure universal dial gauge bracket -VW 387- to housing.

– Fit dial gauge with dial gauge extension -VW 382/10- (6 mm
flat).
– Adjust measuring lever -VW 388- to distance “a” = 79 mm (for
∅ 188 mm crown wheel).
Measure play between teeth faces (backlash) as follows:
– Turn crown wheel until it makes contact with the face of one
tooth (end of backlash travel).
– Preload dial gauge to 2 mm and set to “0”.
– Turn back crown wheel until it makes contact with opposite
tooth face (backlash).
– Take backlash reading and note down measured value.
– Turn crown wheel through 90° and repeat measurements a
further 3 times.

Note
If the pinion shaft turns when taking the measurement, it can be

locked by engaging 2 gears at the same time, (e.g. reverse gear
-arrow A- and 1st gear -arrow B-.
Determining average backlash

– Add the four measured values together and divide by four.
Example:
1st measured value 0.28 mm
+ 2nd measured value 0.30 mm
+ 3rd measured value 0.30 mm
+ 4th measured value 0.28 mm
= Sum of measured values 1.16 mm
• Result: the average backlash is 1.16 mm : 4 = 0.29 mm
Note
If the individual measurements differ by more than 0.06 mm, this

means that the installation of the crown wheel is not correct or
that the final drive gear set itself is defective. Check installation;
renew final drive gear set if necessary.

Formula: “S2” = “S2*” - measured backlash + specified backlash
Example:
– Measured average backlash 0.29 mm
+ Specified backlash (desired average value for 0.20 mm
backlash)
– Determine shim(s)
by AUDI according to table. For orpart number,
any liabilityrefer
permitted unless authorised AG. AUDI AG does not guarantee accept
to ⇒ toElectronic
with respect the correctnessparts catalogue
of information .
in this document. Copyright by AUDI AG.

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
Formula: “S1” = “Stotal” – “S2”

Example:
– Thickness of shim “S2” 1.21 mm


0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
Checking adjustment
– After installing shims “S1” and “S2permitted
”, turn unless
differential
authorised5byturns
AUDI AG. in AUDI AG does not guarantee or accept any liability
both directions so that the tapered roller bearings settle.
– Measure backlash four times on circumference.

♦ Specification: 0.12 ... 0.28 mm
Note
♦ Adjustment must be repeated if backlash is outside tolerance.

The total shim thickness “Stotal” must remain unchanged.
♦ The discrepancy between individual measured values must
not exceed 0.06 mm.

A0059185920-6-Speed Manual Gearbox 01X Front-Wheel Drive

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Service

Service Department. Technical Information

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Copyright © 2015 Audi AG, Ingolstadt A0059185920

6.2 Exploded view - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Code letters and date of manufacture of gearbox -arrow 1-

Manual gearbox 01X -arrow 2-

1.1 Code letters, allocation, transmission ratios, capacities

Ratio Final drive 32 : 9 = 3.556 31 : 8 = 3.875 30 : 8 = 3.750

Manual gearbox 6-speed 01X (front-wheel drive)

Manual gearbox 6-speed 01X (front-wheel drive)

Manual gearbox 6-speed 01X (front-wheel drive)

2 Rep. Gr.00 - Technical data

Manual gearbox 6-speed 01X (front-wheel drive)

Manual gearbox 6-speed 01X (front-wheel drive)

Ratio Final drive 30 : 8 = 3.750 32 : 9= 3.555

-Arrows- point in direction of travel.

4 Rep. Gr.00 - Technical data

3 Calculating ratio “i”

3. Calculating ratio “i” 5

4 General repair instructions

4.1 Special tools

6 Rep. Gr.00 - Technical data

O-rings, oil seals and gaskets

4. General repair instructions 7

♦ If required, renew the tapered roller bearings on one shaft to‐

8 Rep. Gr.00 - Technical data

Checking synchro-rings with molybdenum coating

4. General repair instructions 9

Checking synchro-rings for 1st and 2nd gear

Abnormal wear on selector gears and locking collars

♦ In comparison: intact synchro-ring or selector gear:

♦ Abnormal wear on locking collar:

10 Rep. Gr.00 - Technical data

♦ In comparison: intact locking collar:

4. General repair instructions 11

Follow steps required when disconnecting battery ⇒ Rep. Gr.

I - Pedal cluster (LHD vehicles)

♦ ⇒ “1.8 Function check for

12 Rep. Gr.30 - Clutch

♦ ⇒ “1.10 Bleeding clutch

1.1 Exploded view - pedal cluster (LHD vehicles)

1. Servicing clutch mechanism 13

1.2 Removing and installing clutch pedal

Clutch pedal switch may only be fitted once so as to ensure a firm

Installation is carried out in reverse sequence; note the following:

• The clutch pedal should be in the normal position (i.e. not

14 Rep. Gr.30 - Clutch

1.3 Removing and installing clutch pedal

1. Servicing clutch mechanism 15

– When installing clutch pedal switch for engine start -F194- ,

1.4 Removing and installing over-centre

16 Rep. Gr.30 - Clutch

1.5 Exploded view - pedal cluster (RHD vehicles)

1. Servicing clutch mechanism 17

1.6 Exploded view - hydraulic system

1 - Brake fluid reservoir