Transmission
Transmission
Center Differential Housing, Center Differential, Spur Gears, Transmission Cover, Input and Output Shafts Together with Transmission-Side Shift Mechanism
• You do not need to remove the differential when removing the components listed above.
• General repair instructions, refer to => [ General Repair Information ] General Repair Information.
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Thrust Piece (40 -105)
• Seal Driver (3013)
• Clamping Sleeve (3116)
• Puller for Wheel Hub (3349)
• Pulling Hook (T20143)
• Subframe Support Assembling Device (T40041)
• Thrust Piece (T40174)
• Gearbox Support (T40206)
• Assembly Tool (T40213)
• Support Tool (T40214)
• Guide Pin (T40216)
• Hot Air Blower (V.A.G 1416)
• Locking fluid (AMV 185 101 A1)
• Sealing paste (AMV 188 001 02)
• Grease for clutch disc shaft splines (G 000 100)
• Adhesive lubricating paste (G 000 150)
• Sealing grease (G 052 128 A1)
Disassembling
- Place the drip tray underneath.
- Remove the plug - arrow - and drain the transmission fluid.
- Secure the (T40206) to the transmission with the bolts - arrows - and tighten it in the assembly stand.
- Remove the clutch module. Refer to => [ Clutch Module ] Clutch Module.
- Carefully set down the clutch module, for example, on a workbench.
- Remove the clutch release lever - 1 - together with the release bearing - 2 - and the spring - 3 -.
- Remove the bolts - 4 -, the locking plate - 5 - (if equipped) and the guide sleeve - 6 -.
- If equipped, remove the transmission neutral position sensor (G701) - A -.
- Remove the bolt - arrow - and remove the sensor from the cover - B -.
• The cover - B - remains installed.
• It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor.
- Remove the bolts - 1 - and pry the selector shaft cover - 2 - off carefully.
- Lift the gearshift shaft - arrow A - and remove it - arrow B -.
- Counterhold the in- and output shafts by sliding the selector rods - 1 - through - 4 - in direction of - arrow -.
• Insert a rag into the gearshift shaft opening between the tool and the housing wall to prevent damaging the transmission cover.
- Push the cover - A - for the output shaft in the center and pry it out in direction of - arrow -.
- Now remove the bolt from the output shaft - A -.
B Allen key 12 mm
C Torque wrench
- Then shift gearshift rails into neutral position.
- Pry out the input shaft seal.
- The locking ring - 1 - in front of the input shaft ball bearing must then be removed.
- Remove the shim - 2 -.
• If it is not possible to remove the locking ring - 1 -, then remove the center differential's transmission cover first and then move the input shaft forward using a rubber hammer.
• The shim - 2 - must definitely be removed before pressing out the shift shaft package so that it does not slide into the locking ring groove.
- Remove the bolts - A - and - arrows - that attach the center differential housing - B - to the transmission cover.
- Carefully remove the center differential housing - 6 -, the pressure spring - 3 -, the adjusting shim - 4 - and the plate spring - 5 -.
- Remove the center differential - 2 - and the gear carrier - 1 -.
If the gear carrier - 1 - remains in the center differential housing, proceed as follows:
- Hold the gear carrier - 1 - by one of the side ribs with pliers and remove it in direction of - arrow A -.
- At the same time, carefully hit housing - arrow B - alternating from one side to the other using a rubber hammer.
Do not damage sealing surfaces when doing this.
- Remove the locking ring - 1 - and pull off the output wheel/drive wheel - 2 - from the pinion.
- Remove the spacer sleeve - 3 - and impeller wheel/drive gear - 4 - from the output shaft. Remove the impeller wheel/drive gear's needle bearing at the same time.
- Then turn transmission in assembly bracket so transmission cover - D - faces upward.
- Remove the following bolts: - A - (used for mounting the bearing bracket), bolt - B - (for mounting the reverse shaft) and bolt - C - (for the transmission cover) - D - on the transmission housing - E -.
- Remove the transmission cover - D -, while being careful of the ball bearing on the input shaft (do not tilt the transmission cover when removing it).
• The ball bearing that is located at the back of the input shaft has a sliding fit in the transmission cover.
- Remove the reverse wheel with reverse shaft - 1 -.
- Remove the oil catch tray - 2 - from the bearing bracket - 3 - - arrows A - and - arrow B -.
- Remove the magnet - 4 - and the oil guide element - 5 - from the transmission housing.
- Attach the (T40213) to the (T40206) using the bolts - arrows -.
There is a danger of causing damage to the toothed gears, the shafts and bearings.
• The input and output shafts must be removed together.
• It is permissible to remove the shaft alternating from side to side by turning each spindle maximum one turn.
• Pay special attention to synchronizing the reverse gear when removing the shift shaft package. It must not slide off of the output shaft!
- Remove the input and output shafts from the ball bearings inside the transmission housing by turning the spindles on the (T40213) one turn and alternating from side to side. Make sure the shift shaft package does not get dropped (get another technician to help you).
- Remove the in- and output shaft and the shift fork group from the transmission housing.
Assembling
• The adjusting shim used for pre-loading the bearing on the impeller wheel/drive gear's tapered roller bearing must be determined again whenever replacing the transmission cover, the impeller wheel/drive gear, its tapered roller bearing, the bearing shield or the center differential housing. Refer to => [ Drive Wheel/Spur Gear Tapered Roller Bearing Pre-Load, Determining ] Drive Wheel/Spur Gear Tapered Roller Bearing Pre-Load, Determining.
Use an assembly tool as follows to keep the synchronization for the reverse gear from sliding apart when installing the shift shaft package:
- Install an extracting hook from the (3349) on the (T40041) , as shown in the illustration.
- Next, position the assembly tool and the extraction hook on the reverse gear synchronizer hub - A - and on the third gear wheel - C - and tighten it down.
• The threaded spindle must not protrude past the (T40041) on the extraction hook - arrow -.
• The assembly tool must be positioned within the radius of the transmission support - D -.
- Use some grease to attach the thrust washer - B - onto the reverse gear synchronizer hub - A -.
- Mount the (3116) on the output shaft.
- Attach the mounts (T40214/1) and (T40214/2) to the transmission housing using the bolts - 1 - (6 in all), as illustrated.
- Install the plate (T40213/1) using the bolts - 2 - on the mounts (T40214/1 and T40214/2).
- Turn the spindle - 3 - back until it hits the end stop and position the spindle - 4 - in the center.
- Turn the transmission housing with the attached special tools in the assembly stands horizontally, as shown in the illustration.
- Heat up the ball bearing in the transmission housing using a (V.A.G 1416).
- First, guide the shift shaft package - 5 - underneath the plate (T40213/1) in the direction of - arrow A -.
- Next, install the shift shaft package and the driveshaft in the transmission housing in direction of - arrow B -.
- Keep the shift shaft package in this position and attach both of the spindles (T40213/2) to the shafts. The gearshift rails - 6 - must be aligned with the bearing areas in the transmission housing.
• Due to the clearance the ball bearings have in the shift shaft package, the shift shaft package for some transmissions can be pressed all the way into the transmission housing by hand.
- After doing this, turn the transmission in the assembly bracket and the shift shaft package so that they face up.
- If necessary, align the spindles (T40213/2) with the shafts again so that the spindles press in the center of the shafts.
There is a danger of causing damage to the toothed gears, the shafts and bearings.
• The input and output shafts must be installed together.
• It is permissible to install the shaft alternating from side to side by turning each spindle maximum one turn.
- Then install the input and output shafts all the way into the ball bearing by turning the spindles (T40213/2) one turn alternating from side to side.
• Don't tilt the shafts when pressing them in. Guide the shift rails into their bearing areas in the transmission housing.
• Remove the (T40041) before fastening the extraction hook on the housing rib - arrow -.
• Pay special attention to synchronizing the reverse gear! The intermediate ring tabs must lock in the reverse gear synchronizer hub!
- Remove the (T40213) and the (T40214).
- Install the magnet - 4 - and the oil guide element - 5 - in the transmission housing.
- Position the oil catch tray - 2 - on the pins - arrow B - located on the bearing support - 3 - and then clip them onto the bearing support - arrows A -.
- Install the reverse drive gear and the reverse shaft - 1 -, while also aligning the threaded opening - arrow C - with the locating bore - arrow D - for the clutch slave cylinder.
- Check whether there are 2 alignment pins for centering the transmission cover/transmission housing in the transmission housing or transmission cover.
- Apply sealing paste (AMV 188 001 02) evenly and not to thick on transmission housing joint surfaces at transmission cover.
- Place the transmission cover - D - on the transmission housing - E -; don't - C - install bolts yet.
- Hand tighten the bolt - B - into the reverse shaft.
- Clean bolt threads - A - with a wire brush. Install the bolts with locking fluid (AMV 185 101 A1) and hand-tighten them into the bearing bracket.
- Tighten the bolts - C - using the specified torque.
- Then tighten the bolts - A - and - B - to the specified torque.
- Place the shim - 2 - on the input shaft.
Determine the Input Shaft Locking Ring- 1 -
- Determine thickest circlip which can still just be installed and insert it. For the correct part number, refer to the electronic parts catalog ETKA
• Begin with the thickest locking ring.
The following locking rings are available:
- Mount the impeller wheel/drive gear - 4 -, needle bearing => [ (Item 21) Needle Bearing ] Left Flange Shaft, Clutch Module, Spur Gears, Gearshift Shaft and Transmission Cover Overview and the spacer sleeve - 3 - on the output shaft.
• If the transmission cover, the impeller wheel/drive gear or the center differential is replaced, you will have to redetermine the shim for pre-loading the center differential's ball bearing. Refer to => [ Bearing Pre-load for Ball Bearings for the Center Differential, Redetermining ] Bearing Pre-Load For Ball Bearings For the Center Differential, Redetermining.
- Place the output gear/drive gear - 2 - on the pinion and install the locking ring - 1 -.
Install the gear carrier - 1 - on the transmission cover as follows:
• Installed position: The tab - arrow A - on the gear carrier - 1 - must installed into the opening - arrow B - inside the transmission cover.
- Slide the center differential - 2 - all the way in direction of the gear carrier - 1 -.
- Insert the plate spring - 5 -, the adjustment shim(s) - 4 - and the spring - 3 - in the center differential housing - 6 -.
• Plate spring installed location - 5 -: The camber on the inner diameter - arrow - faces toward the center differential housing - 6 -.
- Apply sealing compound (AMV 188 001 02) evenly and not too thickly.
- Then position the center differential housing - 6 - on the transmission.
- Press the center differential housing - B - on until it makes contact with the transmission cover and hold it securely.
- Install bolts - A -, including new bolts, - arrows - and tighten to the specified torque.
- Counterhold the in- and output shafts by sliding the selector rods - 1 - through - 4 - in the direction of - arrow -.
• Insert a rag into the gearshift shaft opening between the tool and the housing wall to prevent damaging the transmission cover.
- Tighten down the new output shaft bolt - A - to the specified torque.
B Allen key 12 mm
C Torque wrench
- Then shift gearshift rails into neutral position.
- Lightly coat the cover - A - for the output shaft with oil on the outer circumference and then install it.
->For the Transmission: Audi A5 Coupe 2008 through Transmission Series Number 000760
• Transmission with these transmissions series numbers were installed only in the Audi A5 Coupe from MY 2008.
- Lightly oil outer circumference of new shaft seal for the input shaft.
- Fill the space between the sealing- and dust lip half way with sealing grease (G 052 128 A1).
- Drive the new seal in until it is flush without tilting it.
->->For the Transmission: Audi A4 2008 ; Audi A5 Coupe 2008 from Transmission Series Number 000761
- Lightly oil new seal on outer circumference.
- Fill the space between the sealing- and dust lip half way with sealing grease (G 052 128 A1).
- Drive in the new sealing ring with (T40174) all the way on without tilting the sealing ring.
Continuation for All Transmissions
- Apply the sealing compound (AMV 188 001 02) evenly and not too thickly on the sealing surface on the transmission cover.
- Install the (T40216) on the selector shaft - 1 -.
- Install the gearshift shaft into the transmission - arrow A - and lift it slightly - arrow B -.
- Bring the selector shaft cover - 2 - into contact with the transmission cover.
- Clean the bolt threads - 1 - with a wire brush. Then install and tighten the bolts with locking fluid (AMV 185 101 A1).
- Remove the guide pin (T40216).
- If equipped, install the transmission neutral position sensor (G701) - A - with a new O-ring in the gearshift shaft cover - B -.
- Clean bolt threads - arrow - with a wire brush. Then install and tighten the bolts with locking fluid (AMV 185 101 A1).
- Install the guide sleeve - 6 - and the locking plate - 5 -, if equipped.
- Clean the bolt threads - 4 - with a wire brush. Then install and tighten the bolts with locking compound (AMV 185 101 A1) => [ (Item 6) Bolt ] Clutch Release Mechanism Overview to the tightening specification.
Rattling noises when using the clutch
• Rattling noises can occur when pressing the clutch if there is not enough grease on the release bearings - 2 -.
• Lubricate the release bearings generously with adhesive lubricating paste (G 000 150). Refer to => [ Lubricating the Release Bearing ] Clutch Release Mechanism Overview.
• Remove any grease still in the guide sleeve bearing area - mounting for the release bearing on the guide sleeve.
- Install the clutch release lever - 1 - together with the release bearing - 2 - and the spring - 3 -. Refer to => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.
- Install the clutch module and the left flange shaft => [ Installing ] Clutch Module.
- Fill transmission fluid and check transmission fluid level in manual transmission.