6 Box - 0a8 Front Wheel Drive

Service
Workshop Manual
Audi A1 2011 ➤
Audi A1 Sportback 2012 ➤
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
6-speed manual gearbox 0A8, front-wheel drive

with respect to the correctness of information in this document. Copyright by AUDI AG.
Edition 03.2014
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 - unless
permitted frontauthorised
differential
by AUDI AG. AUDI AG does not guarantee or accept any liability
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 D3E804022FF

Audi A1 2011 ➤ , Audi A1 Sportback 2012 ➤
6-speed manual gearbox 0A8, front-wheel drive - Edition 03.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Calculating gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Transmission layout - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 6
5 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Exploded view - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Exploded view - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 26
1.7 Removing and installing lines for clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.8 Bleeding clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.9 Checking clutch
permittedmaster cylinder
unless authorised and
by AUDI AG.clutch
AUDI AGslave cylinder
does not guarantee or .accept
. . . any
. . liability
.................. 30
1.10 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Exploded view - clutch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Exploded view - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Exploded view - selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.9 Removing and installing selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.10 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents i
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Exploded view - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.3 Exploded view - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 Exploded view - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.5 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.6 Exploded view - input shaft, output shafts, differential and selector rods . . . . . . . . . . . . . . 85
6.7 Servicing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.8 Removing and installing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.9 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.1 Exploded view - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2 Exploded view - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.3 Servicing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.4 Servicing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Exploded view - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Overview of fitting locations - oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.3 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.4 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.5 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
ii Contents
00 – Technical data
1 Identification
(ARL003741; Edition 03.2014)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification

The 6-speed manual gearbox 0A8, front-wheel drive is installed
in the Audi A1 2011 ►
⇒ “2.1 Allocation of gearbox to engine”, page 2 .
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 0A8 -arrow 2-
Manual gearbox 0A8 -arrow 2-
Code letters and production date of gearbox -arrow-

Example: MPG 14 06 1
I I I I
I I I I
Code letters Day Month Year (2011)
of manufacture
Additional data are manufacture-related.
Note
The code letters for the gearbox are also given on the vehicle data
stickers.
1. Identification 1
2 Technical data
⇒ “2.1 Allocation of gearbox to engine”, page 2
⇒ “2.2 Capacities”, page 3
⇒ “2.3 Calculating gear ratios”, page 3
2.1 Allocation of gearbox to engine

Manual gearbox 6-speed 0A8 (front-wheel drive)
Code letters LNK NJU NKL
Manufactured from 09.11 03.13 09.11
to
Allocation Model Audi A1 2011 ► Audi A1 2011 ► Audi A1 2011 ►
Engine 2.0 ltr. - 105 kW TDI 1.4 ltr. - 103 kW TFSI 2.0 ltr. - 100 kW TDI
2.0 ltr. - 105 kW TDI
Ratio Final drive I 68 : 21 = 3.238 69 : 20 = 3.450 68 : 21 = 3.238
for 1st to 4th
gear
Z2 : Z1 = i Final drive II 68 : 26 = 2.615 69 : 25 = 2.760 68 : 26 = 2.615
for 5th/6th gear
and reverse
gear
The following data can be found in the ⇒ Electronic parts catalogue
♦ Individual gear ratios
♦ Allocation of drive shaft flanges
♦ Allocation of clutch type

Code letters PEG QDN
Manufactured from 01.13 04.13
to
Allocation Model Audi A1 2011 ► Audi A1 2011 ►
Engine 2.0 ltr. - 100 kW TDI 1.4 ltr. - 103 kW TFSI
2.0 ltr. - 105 kW TDI
Ratio Final drive I 68 : 21 = 3.238
69 : 20 = 3.450
for 1st to 4th
gear
Z2 : Z1 = i Final drive II 68 : 26 = 2.615 69 : 25 = 2.760
for 5th/6th gear
and reverse
gear
The following data can be found in the ⇒ Electronic parts catalogue
♦ Individual gear ratios
♦ Allocation of drive shaft flanges
♦ Allocation of clutch type
2 Rep. gr.00 - Technical data

2.2 Capacities
Code letters LNK, NJU, NKL, PEG, QDN
Capacity of manual gearbox 2.3 ltr.
♦ Gear oil specifications ⇒ Electronic parts catalogue
2.3 Calculating gear ratios

Example: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6-speed manual 6th gear Final drive

gearbox 0A8
Driving gear ZG1 = 46 ZA1 = 26
Driven gear ZG2 = 33 ZA2 = 68
i = Z2 : Z1 Z1 = number of teeth on driving gear,

Z2 = number of teeth on driven gear
iG = gear ratio = ZG2 : ZG1 = 33 : 46
= 0.717
iA = axle ratio = ZA2 : ZA1 = 68 : 26
= 2.615
iov = overall ratio = iG x iA = 0.717 x 2.615
= 1.876
2. Technical data 3
3 Transmission layout
⇒ “3.1 Transmission layout - front-wheel drive”, page 4
3.1 Transmission layout - front-wheel drive

Identification
-Arrows- point in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th/6th and
reverse gear (output shaft II)
6 - Output shaft for 1st-4th gear
(output shaft I)
7 - Differential permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Ratio
-Arrows- point in direction of travel

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. Transmission layout 5
4 Safety precautions
⇒ “4.1 Safety precautions when working on vehicles with start/
stop system”, page 6
4.1 Safety precautions when working on ve‐

hicles with start/stop system
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).

5 Repair instructions
⇒ “5.1 General repair instructions”, page 7
⇒ “5.2 Contact corrosion”, page 11
5.1 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. 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 - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ For a complete list of special tools used in this Workshop
Manual ⇒ Workshop equipment and special tools .

Gearbox
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ Allocate bolts and other components according to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of
wax and grease.
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 76 .
♦ Capacities ⇒ page 3 , specifications ⇒ Electronic parts cata‐
logue .
Sealants
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealing paste.
♦ Apply sealing paste - AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste.
5. Repair instructions 7
Oil seals, seals, O-rings and gaskets

♦ Always renew seals, O-rings and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ 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 in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of installation depth toleran‐
ces).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ Check oil level after installing new gaskets, O-rings and oil
seals ⇒ page 76 .
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-.

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.
♦ Parts which are particularly sensitive (e.g. clutch pressure
plate) must be kept straight. Loosen and tighten bolts and nuts
in stages and in diagonal sequence.
♦ Always renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Use inductive heater - VAS 6414- to heat inner races of ta‐
pered roller bearings to approx. 100°C before installing. Press
home onto stop when installing so there is no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
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. Install only shims which are in
perfect condition.
♦ Install only shims which are in perfect condition.
Synchro-rings
♦ Do not interchange synchro-rings. When reusing always fit to

the same selector gear.
♦ Check for wear; renew if necessary.
♦ Check the grooves -arrow 1- on synchro-ring -A- and on inner
ring for wear (flattened sections in grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is fitted, check the outer contact
surface -arrow 2- and inner contact surface -arrow 3- of the
intermediate ring for »scoring«, »visible traces of wear« and
»blue discolouration (caused by overheating)«.
♦ Check cone on selector gear for scoring and visible traces of
wear.
♦ Lubricate synchro rings with gear oil before installing.
Gear wheels
♦ Clean before pressing on.
♦ Protected
Use inductive heater - VAS 6414- to heat to approx. 100°C
by copyright. Copying for private or commercial purposes, in part or in whole, is not
before installing.
with respect Pressof home
to the correctness onto
information in thisstop when
document. installing
Copyright by AUDIsoAG.
there is no axial clearance.
Selector gears and locking collars
♦ After installing, check 1st to 5th selector gears for minimal axial
play and freedom of movement.
♦ 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.
Clutch mechanism, clutch
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective, you must first carry out
the appropriate function check ⇒ page 30 .
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the clutch slave
cylinder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the clutch slave cylinder.
♦ 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 30 ).
♦ After installing the slave cylinder, carefully press the clutch
pedal. 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.
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts in a diagonal sequence and in several gradual
stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing,
flywheel and parts of the engine facing the gearbox in order to
prevent odour.
♦ Only blow out dual-mass flywheel with compressed air.
5.2 ContactProtected
corrosion
The gearbox housing and
withclutch
respect tohousing areofmade
the correctness of inathis
information magne‐
document. Copyright by AUDI AG.
sium alloy.
Contact corrosion can occur if unsuitable fasteners are used on
the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.

♦ Damage resulting from contact corrosion is not covered by the
warranty.

6 Electrical components
⇒ “6.1 Overview of fitting locations - electrical components”, page
13
6.1 Overview of fitting locations - electrical

components
Clutch position sender - G476-
Fitting location: the clutch position sender is attached to the clutch
master cylinder.
⇒ “1.10 Removing and installing clutch position sender G476 ”,
page 31
Gearbox neutral position sender - G701- and reversing light

switch - F4-
Gearbox neutral position sender - G701- -1-
Reversing light switch - F4- -2-
Fitting location: behind starter on gearbox
⇒ “6.4 Exploded view - selector unit”, page 82
6. Electrical components 13
30 – Clutch
1 Clutch mechanism
⇒ “1.1 Exploded view - pedal cluster”, page 14
⇒ “1.2 Exploded view - clutch hydraulics”, page 17
⇒ “1.3 Exploded view - clutch release mechanism”, page 19
⇒ “1.4 Removing and installing clutch pedal”, page 20
⇒ “1.5 Removing and installing mounting bracket”, page 22
⇒ “1.6 Removing and installing clutch slave cylinder together with
release bearing”, page 26
⇒ “1.7 Removing and installing lines for clutch hydraulics”,
page 26
⇒ “1.8 Bleeding clutch hydraulics”, page 28
⇒ “1.9 Checking clutch master cylinder and clutch slave cylinder”,
page 30
⇒ “1.10 Removing and installing clutch position sender G476 ”,
page 31 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.1 Exploded view - pedal cluster
14 Rep. gr.30 - Clutch

1 - Clutch pedal
❑ Removing and installing
with over-centre spring
⇒ page 20
2 - Retaining clip
❑ Only renew when clutch
master cylinder has
been removed
❑ Removing ⇒ page 16
❑ Pressing on
⇒ page 16
3 - Clutch master cylinder
⇒ “1.5.1 Removing and
installing mounting
bracket with clutch mas‐
ter cylinder”, page 22
4 - Gasket
❑ Renew
❑ Glue onto clutch master
cylinder
5 - Clutch position sender -
G476-
⇒ page 31
❑ Checking in Guided
Fault Finding ⇒ Vehi‐
cle diagnostic tester
6 - Pivot pin
❑ Cannot be removed
without being damaged
❑ Renew
7 - Plenum chamber partition panel
❑ With mounting for mounting bracket and master cylinder
8 - Bush
❑ For top drilling in mounting bracket
❑ Bushes for bottom drilling in mounting bracket are installed in clutch master cylinder
9 - Nut
❑ 3x
❑ Self-locking
❑ Renew
❑ 25 Nm
10Protected
- Crash bar
❑withSecured tocorrectness
respect to the steering column in this document. Copyright by AUDI AG.
of information
❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube for dash panel;
Exploded view - central tube for dash panel
11 - Bolt
❑ A nut is fitted on some versions ⇒ Electronic parts catalogue
❑ Tightening torque ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube for dash panel; Exploded
view - central tube for dash panel
1. Clutch mechanism 15
12 - Mounting bracket
❑ Removing and installing with clutch master cylinder ⇒ page 22
❑ Removing and installing without clutch master cylinder ⇒ page 24
13 - Stop
❑ For clutch pedal
14 - Over-centre spring
❑ Removing and installing ⇒ page 20
15 - Bearing bushes
16 - Cap
Removing retaining clip

– Lever off retaining clip -A- -arrow-.
Pressing on retaining clip

– Carefully press retaining clip -A- onto operating rod for clutch
master
Protected by cylinder usingforpunch
copyright. Copying private or -commercial
2074- .purposes, in part or in whole, is not

1.2 Exploded view - clutch hydraulics

⇒ “1.2.1 Exploded view - clutch hydraulics, LHD vehicles”,
page 17
⇒ “1.2.2 Exploded view - clutch hydraulics, RHD vehicles”,
page 18
1.2.1 Exploded view - clutch hydraulics, LHD vehicles
1 - Clutch slave cylinder with

release bearing
❑ Can only be renewed af‐
ter removing gearbox
⇒ page 26
2 - Bleeder connection
3 - O-ring
❑ Renew if damaged
❑ Lubricate with brake flu‐
id before installing
4 - Retaining clip authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
❑ Towithremove and install
respect to the correctness of information in this document. Copyright by AUDI AG.
pipe, pull out retaining

clip as far as it will go
5 - Bleeder screw
❑ 4.5 Nm
❑ Bleeding clutch system
⇒ page 28
6 - Dust cap
7 - Retaining clip
❑ To remove and install
8 - O-ring
9 - Brake fluid reservoir
10 - Seal
❑ Must be fitted in supply
hose
11 - Supply hose
12 - Seal
❑ Must be fitted in supply hose
⇒ “1.5.1 Removing and installing mounting bracket with clutch master cylinder”, page 22
14 - Retaining clip
❑ To remove and install pipe, pull out retaining clip as far as it will go
15 - O-ring
❑ Lubricate with brake fluid before installing

16 - Pipe
❑ With frequency modulator
17 - Bracket
❑ Attached to body
1.2.2 Exploded view - clutch hydraulics, RHD vehicles

release bearing
❑ Can only be renewed af‐
ter removing gearbox
⇒ page 26
2 - Bleeder connection
3 - O-ring
4 - Retaining clip
5 - Bleeder screw
❑ 4.5 Nm
❑ Bleeding clutch system
⇒ page 28
6 - Dust cap
7 - Retaining clip
8 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew if damaged with respect to the correctness of information in this document. Copyright by AUDI AG.

9 - Brake fluid reservoir
10 - Seal
❑ Must be fitted in supply
hose
11 - Supply hose
12 - Seal
❑ Must be fitted in supply hose
⇒ “1.5.1 Removing and installing mounting bracket with clutch master cylinder”, page 22
14 - O-ring


15 - Retaining clip
❑ To remove and install pipe, pull out retaining clip as far as it will go
16 - Pipe/hose assembly
17 - Bracket
18 - Bracket
1.3 Exploded view - clutch release mechanism

release bearing
❑ Slave cylinder and re‐
lease bearing are one
unit and can only be re‐
newed together
❑ Do not wash out bear‐
ing; wipe clean only
❑ If bearing is noisy, re‐
new together with slave
cylinder
⇒ page 26
2 - Bolt
❑ 3x
Protected❑ Renew
permitted❑ Tighten
unless authorisedbolts carefully
by AUDI AG. AUDI AGin does not guarantee or accept any liability
several small steps and
in diagonal sequence;
make sure that mount‐
ing lugs on slave cylin‐
der do not break off
❑ 12 Nm for metal clutch
slave cylinder
❑ 15 Nm for plastic clutch
slave cylinder
3 - Retaining clip
4 - Pipe
❑ To clutch master cylin‐
der
⇒ page 26
5 - O-ring
1.4 Removing and installing clutch pedal
Note
If the over-centre spring is being removed on its own, the clutch

pedal does not have to be separated from the clutch master cyl‐
inder.
Special tools and workshop equipment required

♦ Pliers - T10005-
Removing
Note
Pivot pin for clutch pedal cannot be removed without being dam‐
aged.
– Remove dash panel cover (driver side) ⇒ General body re‐

pairs, interior; Rep. gr. 68 ; Shelves / trim panels; Removing
and installing dash panel cover (driver side) .
– Remove crash bar ⇒ General body repairs, interior; Rep. gr.
70 ; Central tube for dash panel; Exploded view - central tube
for dash panel .
– To release operating rod for clutch master cylinder, pull clutch
pedal slightly towards passenger compartment.
– Press both sides of retaining clip inwards using pliers -
T10005- -arrows-.

– Using 8 mm Allen key -item 1-, turn pivot pin for clutch pedal
anti-clockwise -arrow- until ears -B- are horizontal.
Note
♦ Retainers -A- will be destroyed when you do this.

♦ Renew pivot pin.
– Move clutch pedal back and forth to pull out pivot pin.
– Remove over-centre spring and (if necessary) clutch pedal.
Installing
Installation is carried out in reverse sequence; note the following:
• Renew pivot pin.
– Bring clutch pedal into position at clutch master cylinder.
• The retaining clip -2- must be fitted on the master cylinder op‐
erating rod -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press on clutch pedal so that retaining clip snaps into place in
mounting on clutch pedal -3-.
– Working sideways from below, insert over-centre spring into

mounting bracket at point -A- beside operating rod of clutch
master cylinder and beside clutch pedal.
• The bearing recess -arrow- for the actuator on the clutch pedal
must be vertical.
– Attach over-centre spring to actuator on clutch pedal -arrow-.
– Press clutch pedal slightly and slide in new pivot pin.

– Using 8 mm Allen key -item 1-, turn new pivot pin for clutch
pedal clockwise -arrow- until ears -A- are vertical.
• Retainers -B- should engage audibly.
– Install crash bar ⇒ General body repairs, interior; Rep. gr. 70 ;
Central tube for dash panel; Exploded view - central tube for
dash panel .
– Install dash panel cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Shelves / trim panels; Removing and
installing dash panel cover (driver side) .
Tightening torques
♦ ⇒ “1.1 Exploded view - pedal cluster”, page 14
1.5 Removing and installing mounting

bracket
⇒ “1.5.1 Removing and installing mounting bracket with clutch
master cylinder”, page 22
⇒ “1.5.2 Removing and installing mounting bracket without clutch
master cylinder”, page 24
1.5.1 Removing and installing mounting

bracket with clutch master cylinder
♦ Hose clamps, upunless
permitted to 25 mm - by3094-
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Sealing tool - T10249-
Removing
– Vehicles with 2.0 ltr. TDI engine: Remove air cleaner housing
⇒ Rep. gr. 23 ; Air cleaner; Removing and installing air cleaner
housing .

Note
♦ In the following steps make sure that no brake fluid escapes

onto the longitudinal member or onto the gearbox below. If this
does happen, clean the affected area thoroughly.
♦ Place a cloth underneath to catch escaping brake fluid.
– Using hose clamp - 3094- , clamp off supply hose to clutch

master cylinder.
Note
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp -3094- , the supply hose must
be returned to its original shape.
– Disconnect supply hose -1- fromProtected

clutch bymaster
copyright.cylinder
Copying for and
private or commercial purposes, in part or in whole, is not
plug hose using sealing tool - T10249/1- . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -3- from clutch master cylinder.
– Unclip clutch position sender - G476- -arrows A, B- and place
it to one side with electrical connector attached.
Note
-Item 1- can be disregarded.

for dash panel .
Note
When working in the footwell, put cloths on the floor covering to

protect it from possible brake fluid spills.
– Remove nuts -1, 2-.

– Remove mounting bracket -3- with clutch master cylinder.
Installing
Note
Renew self-locking nuts.
– Push supply pipe onto connection on clutch master cylinder

so that retaining clip snaps into place.
– Pull on pipe to check that it is secure.
– Bleed clutch system ⇒ page 28 .
– Install clutch position sender - G476- ⇒ page 31 .
dash panel .


– Install air cleaner housing ⇒ Rep. gr. 23 ; Air cleaner; Re‐
moving and installing air cleaner housing .
Tightening torques
1.5.2 Removing and installing mounting

bracket without clutch master cylinder
♦ Pliers - T10005-
Removing


for dash panel .
– To release operating rod for clutch master cylinder, pull clutch
pedal slightly towards passenger compartment.
– Press both sides of retaining clip inwards using pliers -
T10005- -arrows-.
– Remove nuts -1, 2-.

– Carefully remove mounting bracket -3- (to do this, get a sec‐
ond mechanic to counterhold clutch master cylinder until it is
disengaged from mounting bracket).
Installing
Note
Renew self-locking nuts.
– Bring clutch pedal into position at clutch master cylinder.

• The retaining clip -2- must be fitted on the master cylinder op‐
erating rod -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press on clutch pedal so that retaining clip snaps intoofplace in in this document. Copyright by AUDI AG.
with respect to the correctness information
mounting on clutch pedal -3-.
dash panel .
Tightening torques
1.6 Removing and installing clutch slave

cylinder together with release bearing
Note
Slave cylinder and release bearing are one unit and can only be
renewed together.
Removing
• Gearbox removed
– Release retaining clip -2- with a screwdriver and pull bleeder
connection -4- off pipe -1-.
– Remove bolts -arrows-.

– Take off slave cylinder together with release bearing -A-.
Installing
Caution
Risk of damage to clutch slave cylinder.

♦ The bolts must only be tightened in small steps to avoid
any risk of breaking off the mounting lugs -arrows- on the
clutch slave cylinder.
– Check O-ring -3- for damage and renew if necessary.

– Press bleeder connection -4- onto connection on pipe -1- so
that retaining clip -2- snaps into place.
– Pull on bleeder connection to check it is secure.
Tightening torques
♦ ⇒ “1.3 Exploded view - clutch release mechanism”, page 19
1.7 Removing and installing lines for clutch

hydraulics

♦ Hose clamps, up to 25 mm - 3094-
♦ Engine bung set - VAS 6122-
Removing
housing .
Note
In the following steps make sure that no brake fluid escapes onto
the longitudinal member or onto the gearbox below. If this does
happen, clean the affected area thoroughly.
– Using hose clamp -3094- , clamp off supply hose to clutch

master cylinder.
Note
– Place lint-free cloth under bleeder connection.

– Pull out retaining clip -arrow- as far as it will go and disconnect
line -A- from bleeder connection.
Note
-Item B- can be disregarded.
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
– Place lint-free cloth under clutch master cylinder.

– Pull out retaining clip -arrow- as far as it will go and disconnect
line from clutch master cylinder.
Caution
Catch escaping brake fluid.

♦ Do not operate clutch pedal after pipe has been discon‐
nected.
– Move line clear and remove.

Installing
Note
After removing the hose clamp - 3094- , the supply hose must be
returned to itsunless
original shape.
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Push line onto connection on so that retaining clip snaps into

place.
– Pull on pipe to check that it is secure.
1.8 Bleeding clutch hydraulics


♦ Brake filling and bleeding equipment - VAS 5234-
♦ Brake fluid specification ⇒ Electronic parts catalogue .

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

hydraulic clutch mechanism.
♦ When performing the following steps, make sure that no brake
fluid escapes onto the gearbox.
♦ Before bleeding the clutch system, top up the brake fluid res‐
ervoir to the “max.” marking with brake fluid.
♦ The brake fluid in the clutch system should be changed at the
same intervals as the brake fluid in the brake system ⇒ Main‐

tenance ; Booklet 819 ; Description of work; Brake fluid:

changing (every 2 years) .
– Pull clutch pedal back to rest position.

– Remove cap from bleeder screw -arrow-.
– Connect bleeder hose -A- to pressure hose of fluid collector
bottle.
– Switch on brake filling and bleeding equipment - VAS 5234- .
• Operating pressure 2.0 bar
– Open bleeder screw.
– Pump clutch pedal rapidly all the way in and out by hand 15 to
20 times (approx. 2 times per second).
– Close bleeder screw.
– Switch off brake filling and bleeding equipment - VAS 5234-
and relieve pressure from bleeding equipment.
– Pump clutch pedal all the way in and out 10 times with your
foot.
– Check that clutch system is functioning properly.
Tightening torques
♦ ⇒ “1.2 Exploded view - clutch hydraulics”, page 17
1.9 Checking clutch master cylinder and

clutch slave cylinder
Note
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:

♦ First check whether any noise is coming from the over-centre
spring.
♦ 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 the clutch pedal returns all the way to its initial
position, 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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Check the complete hydraulic system for leaks.with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
♦ Check joint between engine and gearbox for traces of brake
fluid escaping from clutch slave cylinder.
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 28 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
High pedal force:
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 32 .
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.)
♦ Foreign body in clutch system
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 32 .
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel
sleeves).
1.10 Removing and installing clutch position

sender - G476-
Removing
housing .
– Unclip clutch position sender - G476- -arrows A, B-.
– Unplug electrical connector and remove clutch position sender
- G476- .
Note
-Items 1, 2, and 3- can be disregarded.

Installing

– Fit clutch position sender - G476- all the way onto clutch mas‐
ter cylinder (electrical connector should be plugged in before‐
hand).
• Clutch position sender should click into place -arrow A-.
– Check by pulling clutch position sender -arrow B-.
2 Clutch
⇒ “2.1 Exploded view - clutch unit”, page 32
⇒ “2.2 Removing and installing clutch”, page 33
⇒ “2.3 Renewing input shaft oil seal”, page 35
2.1 Exploded view - clutch unit

“Sachs” version
1 - Dual-mass flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Observe instructions for
removal ⇒ page 33
2 - Clutch plate
⇒ page 33
❑ Always renew clutch
pressure plate as well
❑ Installation position
⇒ page 33
❑ For diameter of clutch
plate, refer to ⇒ Elec‐
tronic parts catalogue
3 - Pressure plate
❑ With adjustment mech‐
anism
⇒ page 33
❑ Checking ends of dia‐
phragm spring
⇒ page 33
❑ Checking spring con‐
nections and rivets
⇒ page 33
❑ Always renew clutch plate as well
❑ For correct version, refer to ⇒ Electronic parts catalogue
4 - Bolt
❑ Loosen and tighten bolts consecutively in steps of 90°
❑ M6: 13 Nm
❑ M7: 20 Nm

Installation position of clutch plate

• Marking “Getriebeseite” (gearbox side) faces towards gearbox
Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Note
If required, clutch pressure plate and clutch plate must always be

renewed together. Select the correct clutch plate and clutch pres‐
sure plate according to engine code ⇒ Electronic parts cata‐
logue .
Checking spring connections and rivets

– Check spring connections between clutch pressure plate and
cover for cracks and make sure rivet fastenings are seated
tightly.
• Renew clutch pressure plate if spring connections are dam‐
aged or rivets are loose -arrows-.
Note
If required, clutch pressure plate and clutch plate must always be

renewed together. Select the correct clutch plate and clutch pres‐
sure plate according to engine code ⇒ Electronic parts cata‐
logue .
Instructions for removing dual-mass flywheel

Caution
Take care not to damage dual-mass flywheel.

♦ Remove bolts -B- by hand. Do not use a pneumatic
wrench or impact wrench.
♦ When removing bolts, take care that the bolt heads do not
come into contact with the dual-mass flywheel.
♦ Rotate dual-mass flywheel -A- so that bolts -B- are aligned
centrally behind the holes -arrows-.
2.2 Removing and installing clutch

2. Clutch 33
♦ Counterhold tool - 3067-
♦ Centring mandrel - T10097- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Grease for clutch plate splines - G 000 100-

Removing
• Gearbox removed
To prevent the clutch pressure plate from becoming distorted
during removal (causes clutch grab when driving off), always ad‐
here to the following procedure when unbolting the clutch pres‐
sure plate:
– Apply counter-hold tool - 3067- in order to loosen bolts.
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the clutch pressure plate is released.
– Take off clutch pressure plate and clutch plate.
Installing

Note
♦ Always renew clutch plate and clutch pressure plate together

and select the correct parts according to engine code ⇒ Elec‐
♦ 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 clutch 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 clutch housing,
flywheel and parts of the engine facing the gearbox in order to
reduce the smell of burnt linings.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert bolts.
♦ Checkpermitted
that dowel sleevesbyfor
unless authorised centralising
AUDI engine/gearbox
AG. AUDI AG does areany liability
not guarantee or accept
in the cylinder block; install any missing dowel sleeves.

♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).
– Note installation position of clutch plate ⇒ page 33 .

– Use counterhold tool - 3067- .
– Position clutch pressure plate on dowel pins.
– Use centring mandrel - T10097- to centre clutch plate.
To prevent the clutch pressure plate from becoming distorted
during installation (causes clutch grab when driving off), always
adhere to the following procedure when attaching the clutch pres‐
sure plate:
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with clutch pressure plate.
– Working clockwise, tighten all six bolts consecutively in steps
of 90° (1/4 turn) until the housing makes contact with the fly‐
wheel.
– Tighten all 6 bolts to final torque consecutively in clockwise
direction.
Tightening torques
♦ ⇒ “2.1 Exploded view - clutch unit”, page 32
2.3 Renewing input shaft oil seal

2. Clutch 35
♦ Extractor tool - T20143/1-
♦ Thrust piece - T40008-
♦ Sealing grease - G 052 128 A1-

Removing
– Remove gearbox ⇒ page 56 .
– Remove slave cylinder with release bearing ⇒ page 26 .
– Pry out input shaft oil seal using extractor tool - T20143/1- .
Note
Take care not to damage contact surface for oil seal on input
shaft.
– Pack space between sealing lip and dust lip -arrow- half-full
with sealing grease - G 052 128 A1- .
– Lightly lubricate outer circumference of oil seal with gear oil.

– Drive in oil seal until flush using thrust piece - T40008- .

– Install slave cylinder with release bearing ⇒ page 26 .
– Install gearbox ⇒ page 69 .
2. Clutch 37
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Overview - selector mechanism”, page 38
⇒ “1.2 Exploded view - gear knob and cover”, page 39
⇒ “1.3 Exploded view - selector cables”, page 39
⇒ “1.4 Exploded view - selector mechanism”, page 41
⇒ “1.5 Removing and installing gear knob”, page 43
⇒ “1.6 Removing and installing selector mechanism”, page 44
⇒ “1.7 Adjusting selector mechanism”, page 45
⇒ “1.8 Dismantling and assembling selector mechanism”,
page 48
⇒ “1.9 Removing and installing selector cable”, page 52
1.1 Overview - selector mechanism
1 - Gearbox selector lever

2 - Gear selector cable Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For gear selection with respect to the correctness of information in this document. Copyright by AUDI AG.
movement -arrows A-
3 - Heat shield
4 - Gate selector cable
❑ For gate selection
movement -arrows B-
5 - Gate relay lever
38 Rep. gr.34 - Controls, housing

1.2 Exploded view - gear knob and cover
1 - Gear lever
2 - Clip
❑ Renew
❑ Must be the same as
original equipment ⇒
Electronic parts cata‐
logue
3 - Trim frame
❑ Removing and installingProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ General body repairs,
interior; Rep. gr. 68 ; with respect to the correctness of information in this document. Copyright by AUDI AG.
Centre console; Re‐
moving and installing
trim panel for centre
console
4 - Gear knob
❑ With gear lever boot
⇒ page 43
1.3 Exploded view - selector cables
Note
♦ Lubricate all bearings and moving surfaces.

♦ Select correct type of grease from ⇒ Electronic parts cata‐
logue .
1. Selector mechanism 39
1 - Cable end-piece
❑ Secures gear selector
cable to gearbox selec‐
tor lever
❑ Detaching from gear se‐
lector cable
⇒ page 41
2 - Securing clip
❑ Renew
3 - Retaining clips
❑ Renew
4 - Gear selector cable
❑ Detaching and securing
at gearbox selector lev‐
er ⇒ page 41
⇒ page 52
❑ Adjusting ⇒ page 45
5 - Selector housing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Retaining clips
❑ Renew
❑ Detaching and securing
at gate relay lever
⇒ page 41
⇒ page 52
8 - Cable support bracket
9 - Bolt
❑ 20 Nm
10 - Grommet
11 - Bush
12 - Nut
❑ 20 Nm
13 - Cable end-piece
❑ Secures gate selector cable to gate relay lever
❑ Detaching from gear selector cable ⇒ page 41
14 - Securing clip
❑ Renew

Removing securing clip

– Lift up tab -arrow-.
Detaching and securing gear selector cable and gate selector ca‐
ble
Detaching
– Lift up tab on securing clip -1- to detach securing clip from
gearbox selector lever and then pull gear selector cable off pin.
– Lift up tab on securing clip -2- to detach securing clip from gate
relay lever and then pull gate selector cable off pin.
Securing
Note
♦ Renew securing clips.

♦ Apply a small quantity of grease - G 000 450 02- to the pins.
♦ -Item 3- can be disregarded.
– Press cable onto pin and secure with securing clip.

Detaching cable end-pieces fromwith
gear selector
respect cable ofand
to the correctness gate in this document. Copyright by AUDI AG.
information
selector cable
– Pull locking mechanism forwards -arrow 1- onto stop and then
turn to left -arrow 2- to lock.
– Take cable -B- out of cable end-piece -A-.
1.4 Exploded view - selector mechanism
Note

♦ Select correct type of grease from ⇒ Electronic parts catalogue .
1 - Floor plate
❑ Bend tabs open to re‐
move
❑ Always renew after re‐
moving
2 - Gasket
❑ Renew
3 - Bush
❑ Fitted in gate selector
cable
❑ Renew gate selector ca‐
ble if bush is damaged
4 - Retaining clips
❑ Renew
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
⇒ page 38
6 - Gear selector cable
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector
mechanism
⇒ page 38
7 - Gear lever guide
8 - Ball socket
❑ Will be damaged during removal
❑ Renew
9 - Spring
10 - Securing clip
11 - Damper
12 - Nut
❑ 4x
❑ M8 - 20 Nm
13 - Gasket
❑ Between selector housing and floor
❑ Self-adhesive
❑ Renew
❑ Glue onto selector housing with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - Selector housing
15 - Damping washer
❑ Push onto gear lever as far as bottom stop

16 - Gear lever
❑ Can be removed and installed without removing gear lever guide ⇒ Item 7 (page 42)
1.5 Removing and installing gear knob

♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1275-
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Using removal wedge - 3409- , lift up gear lever boot -1- (as
indicated by -arrows-) and turn inside out over gear knob.
– Open clip -arrow- and pull off gear knob together with boot.
Installing
– Push gear knob together with boot onto gear lever as far as
stop.
– Secure gear knob to gear lever with clip -arrow-, using hose
clip pliers - V.A.G 1275- .
1.6 Removing and installing selector mech‐

anism
Removing
– Remove gear knob with gear lever boot ⇒ page 43 .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove heat shield in centre tunnel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Strips / trim panels / extensions; Explo‐
ded view - heat shield .
housing .
– Remove securing clips -1, 2-.
– Move gear selector cable and gate selector cable clear.
Note
– Remove bolts and nut -arrows- for cable support bracket.

– Remove nuts -arrows- and detach selector mechanism from

below.
Installing
– Align selector housing parallel to body.
• Distance to body must then be the same on both sides.
– Secure cable support bracket -3- to gearbox. At the same time,

hook cables into hook -arrow- (if fitted).
– Apply a small amount of grease to pins of gearbox selector

lever and gate relay lever.
• Select correct type of grease from ⇒ Electronic parts cata‐
logue .
– Fit gear selector cable -2- and gate selector cable -3- with new
securing clips -1, 4- onto gear selector lever and gate relay
lever.
– Adjust selector mechanism ⇒ page 45 .
– Install heat shield in centre tunnel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Strips / trim panels / extensions; Explo‐
ded view - heat shield .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install gear knob with gear lever boot ⇒ page 43 .
Tightening torques
♦ ⇒ “1.3 Exploded view - selector cables”, page 39
♦ ⇒ “1.4 Exploded view - selector mechanism”, page 41
1.7 Adjusting selector mechanism

♦ Removal wedge - 3409-
♦ Locking pin - T10027A-
Requirements for adjustment

• 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.
Adjusting
– Using removal wedge - 3409- , lift up gear lever boot -1- (as
indicated by -arrows-) and turn inside out over gear knob.
– Open ashtray (if fitted).
– With gearbox in neutral, move gear lever to the left into 1st/
2nd gear gate.

– If fitted, pull noise insulation slightly to one side.

– Fix gear lever in position with locking pin - T10027A- .
Note
The noise insulation panels are removed to give a better illustra‐

tion.
housing .
Release cable end-pieces for gear selector cable and gate se‐
lector cable as follows:
– Push locking sleeves on gear selector cable and gate selector
cable forward as far as they will go -arrow 1-.
– Turn locking sleeve as far as stop in direction of -arrow 2- so
that it engages.
• It should now be possible to move the cables in the cable end-
pieces.
• Gearbox in neutral.
Lock selector shaft as follows:

– Push gearbox selector lever down into 1st/2nd gear gate
-arrow 1-. At the same time, turn angled rod -A- in direction of
-arrow 3- and press it inwards in direction of -arrow 2- until it
engages.
• The selector shaft is then locked and can no longer be moved.
– Ensure that the gear selector cable and the gate selector cable
are located free of tension in the cable end-pieces.
– Turn locking sleeves on gear selector cable and gate selector

cable as far as they will go -arrows-.
• The spring presses the locking sleeve back into the original
position.
Note
Cable adjustment is now complete.
– Turn angled rod -A- back to initial position in direction of

-arrow 2-, at the same time pulling it out in direction of
-arrow 1-.
– Remove locking pin - T10027A- .
Checking adjustment
• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Depress clutch.
– Select all gears several times. Pay particular attention to the
operation of the reverse gear locking mechanism.
Should a gear fail to engage smoothly after repeated selection,
readjust selector mechanism ⇒ page 45 .
1.8 Dismantling and assembling selector

mechanism
♦ Press tool - VW 412-
♦ Adapters - 10 - 222 A /25-

♦ Assembly tool - T10178-
♦ Release tool - T10236-
♦ Wedge - T10357-
♦ Counter-support Kukko series 16

Dismantling
• Selector mechanism removed ⇒ page 44 .
– Open out tabs -arrows- all round with screwdriver and remove
floor plate.
– Remove gasket.
– Detach retaining clip -2-.

– Press off gear selector cable -1- using release tool - T10236- .
Note
-Items 3 and 4- can be disregarded.
– Hold gear lever -3- firmly.

– Push spring -1- in direction of -arrow-.
– Remove securing clip -2-.
– Remove spring.
– Press arm -A- of spring to side until it is located next to damper

-arrow-.
– Move gear lever to side and remove damper.
Note
A second mechanic is required for the following step.
– Working from below, release all four retaining lugs -arrows- on

ball socket by applying a small screwdriver at each lug.
– At the same time press gear lever out of selector housing to‐
gether with ball socket and gear lever guide.

– Press ball socket -2- off ball -1- in gear lever guide.
– To do so, pull ball socket upwards -arrow A- and turn ball
socket in direction of -arrow B- to release it from gear lever
guide.
Assembling
Assembly is carried out in reverse sequence; note the following:
Note
♦ Renew seals and gaskets.

♦ Select correct type of grease from ⇒ Electronic parts cata‐
logue .
– First fit ball socket over ball in gear lever guide and then press
ball socket into selector housing until retaining lugs -arrows-
snap into place.
– Press gear selector cable -1- onto gearbox selector lever.

– Secure gear selector cable with retaining clip -2-.
Install floor plate as follows:

– Fit gasket onto floor plate.
Caution
Risk of damage to selector housing and floor plate.

♦ Apply only light pressure when pre-tensioning selector
housing.
– Secure selector mechanism and floor plate using tools, as

shown in illustration.
A - Counter-support, e.g. Kukko series 16
– Lever tabs -arrows- of floor plate over rim of selector housing
on both sides using wedge - T10357- .
– Install selector mechanism ⇒ page 44 .
1.9 Removing and installing selector cable

Removing
– Remove selector mechanism ⇒ page 44 .
– Open out tabs -arrows- all round with screwdriver and remove
floor plate.
– Remove gasket.
– Detach retaining clips -2, 3-.

– Press off gear selector cable -1- and gate selector cable -4-
using a screwdriver.
Release cable end-pieces -A- for gate selector cable and gear
selector cable -B- as follows:
– Push locking sleeve forwards as far as stop -arrow 1-.
– Turn locking sleeve clockwise as far as stop -arrow 2- so that
it engages.
– Detach cable end-pieces from selector cables. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Pull off securing clips -1- and -2-.

– Detach cable support bracket from selector cables.
Installing
Note
Renew gate selector cable if bush ⇒ Item 3 (page 42) is damaged.
– Fit gasket and install floor plate -arrows- ⇒ page 52 .

– Install selector mechanism ⇒ page 44 .
1.10 Renewing selector shaft oil seal

♦ Tube - VW 423-
♦ Extractor tool -byT20143/1-

Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing
housing .
– Detach securing clip -1- and pull gear selector cable -2- off
gearbox selector lever.
– Detach securing clip -4- and pull gate selector cable -3- off
gate relay lever.
– Remove securing clip -1- and detach gate relay lever -4- to‐
gether with slide block -arrow-.

– Remove gearbox selector lever -3- from selector shaft by re‐
moving nut -2-.
– Pull out selector shaft oil seal with extractor tool - T20143/1- .
Installing
– Lightly oil outer circumference of new oil seal.
– Pack space between sealing lip and dust lip -arrow- half full

– Drive in oil seal with tube - VW 423- .
– Install gearbox selector lever so that the gapwith
in the splines
-arrow A- aligns with the wider spline -arrow B- on the selector
shaft.
– Tighten new nut -2- securing gear selector lever -3- to selector
shaft to specified torque ⇒ Item 9 (page 82) .
• Before installing gate relay lever -4-, check that bearing bush‐
es ⇒ Item 7 (page 82) are fitted in selector unit.
• Lubricate bearings of gate relay lever and slide block -arrow-
in gear selector lever. Select correct type of grease from ⇒
Electronic parts catalogue .
– Fit new securing clip -1- on gate relay lever.
– Apply a small amount of grease to pins of gearbox selector
lever and gate relay lever.
• Select correct type of grease from ⇒ Electronic parts cata‐
logue .
– Fit gear selector cable -2- and gate selector cable -3- with new
securing clips -1, 4- onto gear selector lever and gate relay
lever.
2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 56
⇒ “2.2 Installing gearbox”, page 69
⇒ “2.3 Tightening torques for gearbox”, page 72
2.1 Removing gearbox

⇒ “2.1.1 Removing gearbox (vehicles with 1.4 ltr. TFSI engine)”,
page 56
⇒ “2.1.2 Removing gearbox (vehicles with 2.0 ltr. TDI engine)”,
page 61
2.1.1 Removing gearbox (vehicles with 1.4 ltr. TFSI engine)
Special tools and workshop

equipment required
♦ Adapter -VW 771/40-
♦ Support bracket - 10 - 222
A-
♦ Hose clamps, up to 25 mm
- 3094-
♦ Gearbox support - 3282-
♦ Pin - 3282/29-
♦ Adjustment plate - 3282/33- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine bung set - VAS 6122-
♦ Engine support bracket, supplementary set - T40093-
Procedure
Note
Re-attach all cable ties at the same locations when re-installing.
– Remove air cleaner housing ⇒ Rep. gr. 24 ; Air cleaner; Re‐

2. Removing and installing gearbox 57

– Release hose clip -1- and remove air pipe.
Note
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

Removing and installing starter
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe with steer‐
ing rack .
– Unbolt drive shafts (left and right) from flange shafts of gear‐
box ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .

– Remove securing clip -3- and detach gate relay lever.
– Unscrew bolts and nut -arrows-, remove cable support bracket

and place to one side together with cables.
– Vehicles with plastic pipe between clutch master and slave

cylinders: clamp off supply hose at brake fluid reservoir using
hose clamp -3094- .
Note


– Pull retaining clip -arrow- out as far as stop.
– Pull plastic pipe or pipe/hose assembly -A- out of bleeder con‐
nection.
Note
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from bleeder connection on clutch slave cylinder.
– Vehicles with start/stop system: unplug electrical connector

-4- from gearbox neutral position sender - G701- .
– Unplug electrical connector -3- at reversing light switch - F4- .
Note
– Remove nuts -1- and bolt -3- and press electronics box -2- to
one side.
– Remove bolts -2 and 3- (accessible from above).
Note
Other items can be disregarded.

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

as shown in illustration.
– Engage hook of spindle - 10 - 222 A /11- in engine lifting eye
(front left).
– Partly take up weight of engine/gearbox assembly.
– Remove bolts -arrows- from gearbox mounting.
– Lower engine/gearbox assembly at spindle - 10 - 222 A /11-

until distance -a- is obtained between gearbox support and
gearbox mounting.
• Dimension -a- = 55 mm
– Remove bolts -arrows- and detach gearbox support.


To remove gearbox “0A8”, set up gearbox support - 3282- with

adjustment plate - 3282/33- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Bolt on support elements -A-, as illustrated on adjustment
plate.
– In place of support element -C-, screw in pin - 3282/29- .
– Place engine and gearbox jack - V.A.G 1383 A- underneath
vehicle.
• The arrow symbol -B- on the adjustment plate points in the
direction of travel.
– Align adjustment plate - 3282/33- parallel with gearbox.
– Remove bolt -C- securing with
gearbox totheengine.
respect to correctness of information in this document. Copyright by AUDI AG.
– Secure adapter -VW 771/40- to threaded hole in gearbox

housing, as shown in illustration.
– Secure gearbox to gearbox support - 3282- with bolt M10x20
-item A-.
• Pin -B- should be flush with underside of guide of gearbox
support - 3282- -arrow-.
– Support gearbox from underneath by raising engine and gear‐
box jack -V.A.G 1383 A- .
– Remove remaining engine/gearbox securing bolts -6 … 9-.

– Press gearbox off dowel sleeves.
– Pull gearbox off engine.
– Lift engine slightly with spindle and push towards right side of
vehicle, paying attention to refrigerant lines.
– Carefully lower gearbox using engine and gearbox jack -
V.A.G 1383 A- .
– While lowering gearbox, adjust position of gearbox using spin‐
dles on gearbox support - 3282- .
Note
When installing a replacement gearbox, the gearbox selector lev‐

er and the gate relay lever have to be transferred from the old
gearbox to the new one ⇒ page 39 .
2.1.2 Removing gearbox (vehicles with 2.0 ltr. TDI engine)


equipment required
♦ Adapter -VW 771/40-
♦ Support bracket - 10 - 222
A-
♦ Hook - 10 - 222 A /10-
♦ Adapter - 10 - 222 A /19-
♦ Removal lever - 80 - 200-
♦ Hose clamps, up to 25 mm
- 3094-

♦ Gearbox support - 3282-

♦ Pin - 3282/29-
♦ Adjustment plate - 3282/33-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Engine bung set - VAS
6122-
♦ Engine support bracket, ba‐
sic set - T40091-
♦ Engine support bracket, supplementary set - T40093-
♦ Bolt M10x20
Procedure
Note
Re-attach all cable ties at the same locations when re-installing.

– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover

panel; Removing and installing engine cover panel .
– Remove air cleaner housing ⇒ Rep. gr. 23 ; Air cleaner; Re‐
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter
– Remove radiator cowl ⇒ Rep. gr. 19 ; Radiators/radiator fans;
Removing and installing radiator cowl .
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
ing rack .
– Remove flange shaft (right-side) ⇒ page 180 .
– Unbolt drive shaft (left-side) from flange shaft of gearbox ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft .
– Remove securing clip -3- and detach gate relay lever.
– Unscrew bolts and nut -arrows-, remove cable support bracket

and place to one side together with cables.
– Vehicles with plastic pipe between clutch master and slave

cylinders: clamp off supply hose at brake fluid reservoir using
hose clamp -3094- .
Note with respect to the correctness of information in this document. Copyright by AUDI AG.


– Pull retaining clip -arrow- out as far as stop.
– Pull plastic pipe or pipe/hose assembly -A- out of bleeder con‐
nection.
Note
Caution

♦ Do not operate clutch pedal after detaching pipe/hose as‐
sembly from bleeder connection on clutch slave cylinder.
– Press release tabs and disconnect crankcase breather hose

-1-.
– Remove bolt -2-, swivel air pipe and connection to rear and
detach from turbocharger.
Note
– Vehicles with start/stop system: unplug electrical connector

-4- from gearbox neutral position sender - G701- .
– Unplug electrical connector -3- at reversing light switch - F4- .
Note
– Remove nuts -1- and bolt -3- and press electronics box -2- to
one side.

– Remove bolts -arrows-.

– Move electrical wiring and hoses clear at air pipe (left-side)
using removal lever - 80 - 200- .
– Release hose clip -3- and detach air pipe (left-side).
– Remove vacuum hose -arrow 1- (leading to brake servo) to‐

gether with grommet -arrow 2-.
– Remove bolts -1- (accessible from above).
Note
Other items can be disregarded.
Vehicles without air conditioner:

– Set up support bracket - 10 - 222 A- on wing mounting flanges,
as shown in illustration.
– Engage hook of -10 - 222 A /10- in engine lifting eye (rear left).

– Attach remaining parts of support bracket as shown in illus‐

tration.
– Attach remaining parts of support bracket as shown in illus‐

tration.
– Engage hook of spindle - 10 - 222 A /11- in engine lifting eye
(front left).
– Pre-tension hook - 10 - 222 A /10- and spindle - 10 - 222 A /
11- .
Vehicles with air conditioner:

– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing bumper cov‐
er .
– Set up support bracket - 10 - 222 A- on top edges of body
flanges (left and right) and on impact bar, as shown in illus‐
tration.
– Attach hooks of spindles -10 - 222 A /11- to engine lifting eyes.
– Apply light tension to spindles.
Continued for all vehicles:

– Remove bolts -arrows- from gearbox mounting.

– Lower engine/gearbox assembly using spindle of support

bracket - 10 - 222 A- until distance -a- is obtained between
gearbox support and gearbox mounting.
• Dimension -a- = 100 mm … 110 mm.
– Remove bolts -arrows- and detach gearbox support.
To remove gearbox “0A8”, set up gearbox support - 3282- with

adjustment plate - 3282/33- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Bolt on support elements -A-, as illustrated on adjustment
plate.
– In place of support element -C-, screw in pin - 3282/29- .
vehicle.
• The arrow symbol -B- on the adjustment plate points in the
direction of travel.
– Align adjustment plate - 3282/33- parallel with gearbox.
– Remove bolt -C- securing gearbox to engine.

– Secure adapter -VW 771/40- to threaded hole in gearbox
housing, as shown in illustration.
– Secure gearbox to gearbox support - 3282- with bolt M10x20
-item A-.
• Pin -B- should be flush with underside of guide of gearbox
support - 3282- -arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Support gearbox from underneath by raising engine and gear‐
box jack -V.A.G 1383 A- .

– Remove remaining engine/gearbox securing bolts -3, 4-.

– Press gearbox off dowel sleeves.
– Pull gearbox off engine.
– Lift engine slightly with spindles and push towards right side
of vehicle, paying attention to refrigerant lines.
– Carefully lower gearbox using engine and gearbox jack -
V.A.G 1383 A- .
– While lowering gearbox, adjust position of gearbox using spin‐
dles on gearbox support - 3282- .
Note
When installing a replacement gearbox, the gearbox selector lev‐

er and the gate relay lever have to be transferred from the old
gearbox to the new one ⇒ page 39 .
2.2 Installing gearbox

♦ Grease for clutch plate splines - G 000 100-
Note
♦ Renew bolts which are tightened by turning through a speci‐

fied angle.
♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Secure all hose connections with the correct hose clips (as
original equipment);
Protectedrefer to ⇒ Copying
by copyright. Electronic parts
for private catalogue
or commercial . in part or in whole, is not
purposes,
♦ Re-attach all cable
withties attothe
respect same locations
the correctness when
of information re-instal‐
in this document. Copyright by AUDI AG.
ling.
♦ After removing the hose clamp - 3094- , the supply hose must
– 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.

– If not already fitted, install dowel sleeves -A- for centralising

engine/gearbox in cylinder block.
Note
If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox noise
(gears will make rattling noises).
– Make sure that intermediate plate is engaged on sealing

flange -top arrow- and fitted onto dowel sleeves
-bottom arrows-.
– Check clutch release bearing for wear and renew if necessary.
vehicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.
– Remove flange shafts when installing a new gearbox or ex‐
change gearbox.
– Check oil seals for flange shafts and renew if necessary: left-
side ⇒ page 166 , right-side ⇒ page 168 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Carefully raise gearbox using engine and gearbox jack - V.A.G

1383 A- .
– Bring gearbox into position.
– Install bottom engine/gearbox securing bolts.
– Detach gearbox support - 3282- with adjustment plate -
3282/33- from gearbox after bolting gearbox and engine to‐
gether.
– Install gearbox support -1- ⇒ page 73 .

– Install top engine/gearbox securing bolts.
– Raise engine/gearbox assembly via spindles of support brack‐
et - 10 - 222 A- .

– Align engine/gearbox assembly in installation position. To do

so, raise engine/gearbox until gearbox support makes full con‐
tact with gearbox mounting.
Caution
The threads in the gearbox support can be damaged if the bolts

are not inserted straight.
♦ Before fitting the bolts -arrows-, the gearbox support and
the support arm of the gearbox mounting must be aligned
absolutely parallel. If necessary, push the gearbox up at
the rear with a trolley jack.
– Bolt gearbox support to gearbox mounting ⇒ page 73 .
WARNING
Risk of accident.
♦ Do not remove support bracket - 10 - 222 A- until all bolts
securing the left-hand engine/gearbox mounting have
been tightened to the specified torque.
– Install pendulum support ⇒ Rep. gr. 10 ; Assembly mountings;

Removing and installing pendulum support .
– Install flange shafts: left-side ⇒ page 179 , right-side
⇒ page 180 .
– Secure drive shafts to flange shafts of gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Exploded view
- drive shaft .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
ing rack .
– Install radiator cowl ⇒ Rep. gr. 19 ; Radiators/radiator fans;
Removing and installing radiator cowl .
– Install bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing bumper cov‐
er .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐
ploded view - starter .
– Assemble selector mechanism ⇒ page 39 .
– permitted
Adjustunless
selector mechanism
authorised ⇒ page
by AUDI AG. AUDI AG does45
not .guarantee or accept any liability
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 76 .
moving and installing air cleaner housing or ⇒ Rep. gr. 24 ;
Air cleaner; Removing and installing air cleaner housing .

2.3 Tightening torques for gearbox
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine or gear oil may be used,
but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques is ± 15 %.
Securing manual gearbox 0A8 to 1.4 ltr. TFSI engine

Item Bolt Nm
1, 9 M12x65 80
2, 3 M12x150 80
4 1)2), 5 1)2) M12x165 80
6 M10x110 40
7, 8 M10x50 40
A Dowel sleeves for centralising
• 1) Centre hex stud.
• 2) Also secures starter.
Securing manual gearbox 0A8 to 2.0 ltr. TDI engine
Item Bolt Nm
1 M12x55 80
2 1) M12x150 80
3 M10x50 40
4 M12x60 80
A Dowel sleeves for centralising
• 1) Also secures starter.
Note

3 Assembly mountings
⇒ “3.1 Exploded view - assembly mountings”, page 73
3.1 Exploded view - assembly mountings
1 - Engine support
2 - Bolt
❑ Tightening torque ⇒
Rep. gr. 10 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
3 - Engine mounting
❑ With support arm
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing engine
mounting
4 - Bolt
mountings; Exploded
ings
5 - Stud
mountings; Exploded
ings
6 - Bolt
mountings; Exploded
ings
7 - Pendulum support
⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing pendulum support
8 - Bolt
❑ Tightening torque ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
9 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Tightening torque ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
10 - Bolt
❑ Renew
❑ 40 Nm +90°
11 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 74
12 - Gearbox mounting
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
3. Assembly mountings 73
13 - Bolt
❑ Renew
❑ 40 Nm +90°
14 - Gearbox support
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
15 - Bolt
❑ Renew
❑ 40 Nm +90°
16 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 74
Gearbox mounting - tightening torque and sequence
Note
Renew bolts which are tightened by turning through a specified

angle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten bolts in 3 stages in the sequence shown: with respect to the correctness of information in this document. Copyright by AUDI AG.
Stage Bolts Tightening torque/tightening angle

1. -A, B, C- Screw in by hand until contact is made
2. -A, B, C- 50 Nm
3. -A, B, C- Turn 90° further

4 Transporting gearbox
♦ Gearbox lifting tackle - 3336-
♦ Workshop hoist - VAS 6100-
– Bolt gearbox lifting tackle - 3336- to clutch housing.
– Set support arm on sliding bracket by means of locking pin
-arrow-.
Number of holes visible = 6
– Lift gearbox with workshop hoist - VAS 6100- and gearbox lift‐
ing tackle - 3336- .
– Set down gearbox as required (for example in transport con‐
tainer).
4. Transporting gearbox 75
5 Gear oil
⇒ “5.1 Checking gear oil level”, page 76
⇒ “5.2 Draining and filling gear oil”, page 76
5.1 Checking gear oil level

♦ Torque wrench - V.A.G 1331-
♦ Multi-point bit - 3357-
Procedure
– Drive vehicle onto a four-column lifting platform or over an in‐
spection pit (vehicle must be horizontal).
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove oil filler plug -arrow- to check gear oil level.
Oil level is correct when gear oil is up topermitted
bottom lip of
unless filler hole.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Top up gear oil if necessary. Specifications ⇒ Electronic parts
catalogue
– Fit new seal on oil filler plug -arrow- and tighten.
Tightening torques
♦ ⇒ Fig. ““Different versions of oil filler/oil drain plug”“ ,
page 111
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
5.2 Draining and filling gear oil


♦ Used oil collection and extraction unit - VAS 6622A-
♦ Gear oil specifications ⇒ Electronic parts catalogue

Draining
– Drive vehicle onto a four-column lifting platform or over an in‐
spection pit (vehicle must be horizontal).
insulation .
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
– Unscrew oil drain plug ⇒ Item 3 (page 110) and allow gear oil
to drain.
– Fit new seal on oil drain plug and tighten.
Filling
– Unscrew oil filler plug -arrow-.
– Fill up gear oil to bottom lip of filler hole.
– Fit new seal on oil filler plug -arrow- and tighten.
Tightening torques
♦ ⇒ Fig. ““Different versions of oil filler/oil drain plug”“ ,
page 111
5. Gear oil 77
6 Dismantling and assembling gearbox

⇒ “6.1 Schematic overview - gearbox”, page 78
⇒ “6.2 Exploded view - gearbox”, page 79
⇒ “6.3 Exploded view - gearbox housing and selector mecha‐
nism”, page 80
⇒ “6.4 Exploded view - selector unit”, page 82
⇒ “6.5 Exploded view - selector forks”, page 84
⇒ “6.6 Exploded view - input shaft, output shafts, differential and
selector rods”, page 85
⇒ “6.7 Servicing selector forks”, page 87
⇒ “6.8 Removing and installing selector unit”, page 88
⇒ “6.9 Dismantling and assembling gearbox”, page 89
6.1 Schematic overview - gearbox
1 - Clutch housing
2 - Reverse shaft
3 - Output shaft for 5th, 6th and
reverse gears
4 - Slave cylinder with release
bearing
5 - Input shaft
6 - Output shaft for 1st - 4th
gear
7 - Differential
8 - Flange shaft (right-side)
9 - Flange shaft (left-side)
10 - 2nd speed selector gear
11 - 1st speed selector gear
12 - 4th speed selector gear
13 - 3rd speed selector gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - 5th speed selector gear with respect to the correctness of information in this document. Copyright by AUDI AG.

16 - Reverse selector gear
17 - Gearbox housing

6.2 Exploded view - gearbox
Note
On gearboxes manufactured from 21 01 8 onwards, the sealing

cap for the input shaft is secured by a circlip -A-.
Assembly sequence for gearbox without circlip -A- for input shaft
sealing cap ⇒ page 89
Assembly sequence for gearbox with circlip -A- for input shaft
sealing cap ⇒ page 89
l - Removing and installing

gearbox housing and selector
mechanism - exploded view
⇒ page 80
ll - Removing and installing in‐
put shaft, output shafts, differ‐
ential and selector rods - ex‐
ploded view ⇒ page 85
6. Dismantling and assembling gearbox 79

6.3 Exploded view - gearbox housing and selector mechanism
1 - Countersunk bolt
⇒ Item 11 (page 171)
2 - Flange shaft with spring
⇒ page 166
❑ Assembling
⇒ page 172
3 - Circlip
❑ For sealing cap
❑ Fitted in gearboxes
manufactured from
21 01 8 onwards
4 - Sealing cap
❑ Secured by circlip in
gearboxes manufac‐
tured from 21 01 8 on‐
wards
(without circlip)
⇒ page 89
(with circlip)
⇒ page 100
❑ Select correct compo‐
nents from ⇒ Electronic
parts catalogue .
5 - Circlip
❑ For grooved ball bearing
on input shaft
6 - Reversing light switch - F4-
❑ 20 Nm
❑ With captive seal (fitted shortly after gearbox was first introduced)
7 - Seal
❑ Not fitted on all gearboxes
8 - Oil drain plug
❑ Tightening torque ⇒ page 111
9 - Seal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always renew with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Locking bolt
❑ 45 Nm
❑ For selector shaft
11 - Bolt
❑ 15 Nm + 90°
❑ Bolt with captive washer available as spare part
❑ Always renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Correct allocation of replacement bolts ⇒ page 81
12 - Bolt
❑ 15 Nm + 90°

❑ Without washer
❑ Always renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Correct allocation of replacement bolts ⇒ page 81
13 - Selector unit
❑ Servicing ⇒ page 82
❑ Removing with gearbox in vehicle ⇒ page 88
14 - Bolt
❑ 20 Nm
❑ Always renew
15 - O-ring
❑ Always renew
16 - Clutch housing
Correct allocation of replacement bolts

A - Bolt with captive washer
B - Bolt without washer
C - Bolt with captive washer

6.4 Exploded view - selector unit
1 - Gearbox housing
2 - O-ring
❑ Renew
3 - Cap
❑ For gearbox breather
4 - Selector unit
❑ Consists of selector
shaftbyand
Protected selector
copyright. Copying for private or commercial purposes, in part or in whole, is not
mechanism cover
❑ Components cannot be
separated from each
other
⇒ page 88
5 - Slide block
6 - Gate relay lever
⇒ page 83
7 - Bearing bush
8 - Gearbox selector lever
⇒ page 83
9 - Nut
❑ Self-locking
❑ Renew
❑ 23 Nm
10 - Oil seal
❑ Lever out with screw‐
driver
❑ Installing ⇒ page 84
11 - Bearing bush
12 - Securing clip
❑ Renew
13 - Bolt
❑ Renew
❑ 20 Nm
14 - Locking bolt
❑ 45 Nm
15 - Angled rod
❑ For adjusting selector mechanism
16 - Seal
❑ Not fitted on all versions
❑ Renew
17 - Reversing light switch - F4-
❑ 20 Nm

❑ Lightly coat lug with MoS2 grease

18 - Bolt
❑ 8 Nm
19 - Gearbox neutral position sender - G701-
20 - O-ring
❑ Renew
Installation position: gearbox selector lever/selector shaft

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.
Installation position: gearbox selector lever/gate relay lever

• Gate relay lever locates in guide rail of gearbox
permittedselector leverby AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
via slide block -arrow-. with respect to the correctness of information in this document. Copyright by AUDI AG.
• Coat slide block and guide rail -arrow- with grease - G 000 450
02- .
Detaching and fitting gate relay lever

Detaching
– Detach gear selector cable -1- and gate selector cable -2-
⇒ page 41 .
– Lift up tab on securing clip -3-, detach clip and pull off gate
relay lever.
Securing
Note
♦ Renew securing clip.

♦ Apply a small quantity of grease - G 000 450 02- to the pin on
the gate relay lever.

Installing oil seal (insert onto stop)
Note
You can also use the tube - VW 423- to fit the selector shaft oil
seal.
6.5 Exploded view - selector forks
1 - Damper rubber
❑ Can be pulled out of and
inserted into selector
rod by hand
2 - Selector rod with selector
fork for 1st and 2nd gear
fork for 3rd and 4th gear
fork for 5th and 6th gear
5 - Reverse gear selector fork
❑ Is mounted on shaft for
reverse gear selector
fork ⇒ page 105
❑ Ball sleeve
⇒ Item 6 (page 84) is
not fitted from gearbox
manufacturing date
06 03 6 onwards
❑ Gradually discontinued
❑ Different types of re‐
verse gear selector
forks are fitted accord‐
ing to version
❑ If shaft for reverse gear
selector fork is not fitted,
selector fork is mounted
on selector rod for 5th/
6th gear selector fork
⇒ page 106
❑ Identification of different
types of reverse gear
selector forks
⇒ page 87
nents from ⇒ Electronic parts catalogue
6 - Ball sleeve
❑ Pulling
Protected outCopying
by copyright. ⇒ page 88 or commercial purposes, in part or in whole, is not
for private
❑ respect
with Pressing in ⇒ page
to the correctness 88
of information in this document. Copyright by AUDI AG.
❑ Ball sleeve is not fitted from gearbox manufacturing date 06 03 6

❑ Gradually discontinued

6.6 Exploded view - input shaft, output shafts, differential and selector rods
1 - Output shaft for 1st - 4th

gear
❑ Dismantling and assem‐
bling ⇒ page 137
⇒ page 86
fork for 1st and 2nd gear
⇒ page 86
fork for 3rd and 4th gear
⇒ page 86
4 - Output shaft for 5th, 6th and
reverse gears
bling ⇒ page 147
⇒ page 86
fork for 5th and 6th gear
⇒ page 86
⇒ page 86
7 - Input shaft
bling ⇒ page 127
❑ Always renew grooved
ball bearing on input
shaft
8 - Reverse shaft
❑ With thrust washer
9 - Thrust washer
10 - Bleeder connection Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Connect to slave cylinder ⇒ Item 14 (page with
85)respect to the correctness of information in this document. Copyright by AUDI AG.
11 - Clutch housing
12 - Input shaft oil seal
❑ Renewing ⇒ page 35
13 - O-ring
❑ Always renew
❑ Push onto pipe connection
14 - Slave cylinder with release bearing

15 - Bolt
❑ 3x
❑ Always renew
❑ Tightening torque ⇒ Item 2 (page 19)
❑ Removing and installing ⇒ Item 11 (page 171)
17 - Flange shaft with spring
❑ Assembling ⇒ page 172
18 - Differential
❑ Dismantling and assembling ⇒ page 172
Installation position of shafts and selector rods in gearbox

1 - Input shaft
2 - Output shaft for 1st - 4th gear
3 - Output shaft for 5th/6th and reverse gear
4 - Reverse shaft
A - Selector rod for 3rd and 4th gear
B - Selector rod for 1st and 2nd gear
C - Selector rod for 5th and 6th gear
D - Reverse gear selector fork * )
1) From gearbox manufacturing date 25 05 9 onwards: mounted on selector rod
for 5th/6th gear selector fork -C-. Identification of different types of reverse gear
selector forks ⇒ page 87

6.7 Servicing selector forks

equipment required
♦ Thrust plate - VW 402-
♦ Tube - VW 426-
♦ Thrust piece - VW 431-
♦ -1- Internal puller - Kukko
21/3-
♦ -4- Counter-support - Kuk‐
ko 22/1-
Identification of different types of reverse gear selector forks

Dimension Reverse gear selec‐ Mounting
“a” (mm) tor fork
24 With ball sleeve On reverse gear se‐
18 Without ball sleeve lector fork shaft
⇒ page 105
15 Without ball sleeve On selector rod with
selector fork for 5th
and 6th gear
⇒ page 106

Pulling out ball sleeve for reverse gear selector fork (up to gear‐
box manufacturing date 05 03 6)
A - Internal puller 18 ... 23 mm , e.g. -Kukko 21/3-
B - Counter-support , e.g. -Kukko 22/1-
Pressing in ball sleeve for reverse gear selector fork (up to gear‐
box manufacturing date 05 03 6)
6.8 Removing and installing selector unit

Removing
housing . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove gearbox selector lever
with⇒ Itemto8the(page
respect 82)of.information in this document. Copyright by AUDI AG.
correctness
– Remove locking bolt -arrow-.
– Put selector shaft in neutral position.

– Remove bolts -arrows- and pull selector unit out of gearbox
housing.

Installing
– Set selector plates in neutral position.
– Apply sealant - AMV 188 200 03- evenly to sealing surface of
selector mechanism cover.
– Position selector shaft so that selector finger -arrow- is en‐
gaged in selector plates.
– Install gearbox selector lever ⇒ page 83 .
Tightening torques
♦ ⇒ “6.4 Exploded view - selector unit”, page 82
6.9 Dismantling and assembling gearbox

⇒ “6.9.1 Dismantling and assembling gearbox (version without
circlip A for input shaft sealing cap)”, page 89
⇒ “6.9.2 Dismantling and assembling gearbox (version with circlip
A for input shaft sealing cap)”, page 100
6.9.1 Dismantling and assembling gearbox

(version without circlip -A- for input shaft
sealing cap)
Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential and selector rods


equipment required
♦ Support plate - VW 309-
♦ Support clamp - VW 313-
♦ Gearbox support - VW 353-
♦ Installing sleeve - VW 455-
♦ Multi-purpose tool - VW
771-
21/01-
♦ -3- Splitter - Kukko 17/0-
ko 22/1-

♦ Support bridge - 30-211A-

♦ Drift - T10169-
♦ Torque wrench - V.A.G
1331-
♦ Hot air blower - V.A.G
1416-
♦ Oil seal extractor lever - VW 681-

♦ Or drift - T10362- instead of -T10169- ⇒ page 119
Removing
– Secure gearbox to assembly stand with bolts -arrows-.
Note
If one of the bolt holes is not flush with the gearbox support ,
please insert a washer (or washers) between the bolt hole and
the gearbox support .
– Turn gearbox on assembly stand so that oil drain plug faces

downwards.
– Protected
Place by drip tray Copying
copyright. underneath.
for private or commercial purposes, in part or in whole, is not
– Drain off gear
with respect oil.
to the correctness of information in this document. Copyright by AUDI AG.
– Pull retaining clip -2- on bleeder connection -4- out as far as it

will go.
– Pull bleeder connection off slave cylinder connection -1-.
Always renew O-ring -3-.
– Remove slave cylinder with release bearing -arrows-.

Make sure that the selector shaft is not locked in position by the
angled rod -arrow- while carrying out the following steps.
– Unscrew locking bolt -2-.
– Then remove bolts -3-.
– Remove reversing light switch - F4- -1-.
– Pull selector shaft -4- out of gearbox housing.
– Remove both flange shafts.
– Remove bolts -B- securing gearbox housing with
from inside
respect to theclutch
correctness of information in this document. Copyright by AUDI AG.
housing.
Note
The hexagon bolt -arrow- is located outside the joint flange. It is

fitted with a washer.
– Lock input shaft by fitting installing sleeve - VW 455- over input

shaft and against clutch housing.
– Tighten splitter -A-, e.g. -Kukko 17/0- behind splines on input
shaft.
The rear side of the splitter must be in contact with installing
sleeve (zero play).
– Pierce rubber in centre of sealing cap -C- with a screwdriver .

– Pull sealing cap out of gearbox housing.
A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 8 ... 12 mm , e.g. -Kukko 21/01-

Detach circlip -C- from grooved ball bearing on input shaft/gear‐

box housing as follows:
– Hold one end of circlip with screwdriver -A-.
– Lever other end of circlip out of slot in grooved ball bearing in
direction of -arrow- with 2nd screwdriver -B-.
– Lever circlip out further by repositioning screwdriver -B-.
– Where fitted, detach spacer -1- from gearbox housing -2-.
• When renewing the gearbox housing, check whether the

spacer has to be re-installed ⇒ page 96 .
– Remove gearbox housing/clutch housing securing bolts -A-.
– Screw adapter VW 771/40 into threaded hole in gearbox hous‐

ing.
– Using hot air blower - V.A.G 1416- , heat area around seat of
input shaft ball bearing in gearbox housing for approx. 10 mi‐
nutes to approx. 100°C.
– Using multi-purpose tool VW 771/1 , pull gearbox housing off
clutch housing in direction of -arrow-.
Note
If necessary, carefully apply a lever to the protruding flanges on

alternate sides of the gearbox housing, taking care not to damage
the sealing surfaces.

– If fitted, detach shim -1- from grooved ball bearing -2-.

– When renewing the gearbox housing, check whether the shim
has to be re-installed ⇒ page 96 .
– Remove splitter -A- and installing sleeve VW 455 from input

shaft.
A second mechanic is required for removing the shafts from the
clutch housing.
– Lift up differential -1- with your left hand.

– With your right hand, lift 1st - 4th gear output shaft together
with selector rods -2- -arrow A-.
– At the same time, the second mechanic must lift the input
shaft, reverse shaft and 5th/6th gear output shaft -3- out of the
clutch housing together with the selector rods -arrow B-.
Note
If required, the differential can be put back in the clutch housing

after lifting the shafts.
– Lever out input shaft oil seal using oil seal extractor lever - VW
681- .
Note
Always renew grooved ball bearing on input shaft

⇒ Item 6 (page 126) .
Installing
• A new grooved ball bearing has been pressed onto the input
shaft ⇒ Item 6 (page 126)

– Insert input shaft -1-, output shaft for 5th and 6th gear -2- to‐
gether with selector rod -3-, selector fork -4- and reverse shaft
-5-.
– Then install differential -1-.
Note
A second mechanic is required for installing the shafts in the

clutch housing.
– Take 1st - 4th gear output shaft -3- with selector rods -4- in
your right hand as illustrated.
– Lift differential slightly with your left hand.
– At the same time, have the second mechanic lift the input shaft
and output shaft for 5th, 6th and reverse gear -2- slightly, to‐
gether with the reverse shaft.
– Now insert 1st - 4th gear output shaft in direction of -arrow-.
The teeth of the input shaft, output shafts and final drive gear/
differential must mesh.
– Now, together with second mechanic, locate shafts and dif‐
ferential in their bearing seats.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Secure support bridge - 30-211A- for input shaft to clutch

housing.
Note
Illustration shows clutch housing turned through 180° for clarity.
– Screw in bolt -A- until input shaft lifts slightly.

From gearbox manufacturing date 10 04 6 to 20 01 8:
A shim is fitted on either side of grooved ball bearing for input
shaft ⇒ Item 6 (page 126) .
Shim (top) Outside diameter 78.6 mm
Shim (bottom) Outside diameter 85 mm

Measuring area above seat for grooved ball bearing

Area above grooved Dimension “a” Shim (top)
ball bearing
Up to gearbox man‐ 10 mm No
ufacturing date
09 04 6
From gearbox man‐ 10.7 mm Yes
ufacturing date
10 04 6 onwards
In the gearbox housing, the area below the seat for the grooved
ball bearing has also been modified -arrow-
Area below bearing seat Shim (bottom)
Up to gearbox man‐ Not modified No
ufacturing date
09 04 6
From gearbox man‐ Slightly deeper Yes
ufacturing date
10 04 6 onwards
– If necessary, fit a shim (outer diameter = 85 mm) -1- onto
grooved ball bearing -2-.
grooved ball bearing for input shaft in gearbox housing for ap‐
prox. 10 minutes to 100°C.

– Fit gearbox housing and tighten new bolts -A-, -B- and -C- to
specified torque.
Allocation of bolts:
– If a shim was fitted on the grooved ball bearing before installing

the gearbox housing, a shim -1- (outer diameter = 78.6 mm)
must also be fitted after installing the gearbox housing -2-
⇒ page 96 .
– Install circlip -1- for input shaft grooved ball bearing.

– Remove support bridge - 30 -211A- for input shaft.
– If stop sleeve for selector shaft has been removed, drive it in
now ⇒ page 119 (drive in until tool reaches stop).
– Turn gearbox on assembly stand so that opening for selector
shaft faces up.
– Insert selector shaft -1- into bottom mounting -2- and into se‐
lector forks -3-.
Note
The sealing cap is removed to give a better illustration.

– Now push selector shaft -1- against stop sleeve -2- in direction
of -arrow- and run selector finger -3- down through selector
forks and onto stop.
• Selector mechanism cover -4- should be parallel to joint sur‐
face on gearbox housing.
• Selector shaft should move up and down easily (gate selector
movement).
Note
If the selector mechanism cover is not parallel with the joint sur‐
face, the selector shaft is not seated in its bottom mounting.
– Tighten bolts -3- for selector mechanism cover -4-.

– Screw in locking bolt -2-; angled rod -arrow- must be released.
– Install reversing light switch - F4- -1-.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings.
– Drive in input shaft oil seal.

– Install slave cylinder with release bearing ⇒ page 19 .
– Select all gears.
– Drive sealing cap into gearbox housing onto stop.

6.9.2 Dismantling and assembling gearbox

(version with circlip -A- for input shaft
sealing cap)
Removing and installing gearbox housing, selector mechanism,

input shaft, output shafts, differential and selector rods Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

equipment required
771-
21/01-
ko 22/1-

♦ Support bridge - 30-211A-

♦ Drift - T10169-
1331-
♦ Hot air blower - V.A.G
1416-
♦ Oil seal extractor lever - VW 681-

♦ Or drift - T10362- instead of -T10169- ⇒ page 119
Removing
– Secure gearbox to assembly stand with bolts -arrows-.
Note
If one of the bolt holes is not flush with the gearbox support ,
please insert a washer (or washers) between the bolt hole and
the gearbox support .
– Turn gearbox on assembly stand so that oil drain plug faces

downwards.
– Place drip tray underneath.
– Drain off gear oil.
– Remove slave cylinder with release bearing

AUDI AG -arrows-.
permitted unless authorised by AUDI AG. does not guarantee or accept any liability
Make sure that the selector shaft is not locked in position by the
angled rod -arrow- while carrying out the following steps.
– Unscrew locking bolt -2-.
– Then remove bolts -3-.
– Remove reversing light switch - F4- -1-.
– Pull selector shaft -4- out of gearbox housing.
– Remove flange shafts.

– Remove bolts -B- securing gearbox housing from inside clutch

housing.
Note
One of the bolts -arrow- is outside the joint flange.
– Lock input shaft by fitting installing sleeve - VW 455- over input

shaft and against clutch housing.
– Tighten splitter -A-, e.g. -Kukko 17/0- behind splines on input
shaft.
The rear sideProtected
of the bysplitter
copyright.must be
Copying for in contact
private with purposes,
or commercial installing
in part or in whole, is not
sleeve (zero play).
– Remove circlip -A- for input shaft sealing cap.
– Pierce rubber in centre of sealing cap -C- with a screwdriver .

– Pull sealing cap out of gearbox housing.

Detach circlip -C- from grooved ball bearing on input shaft/gear‐

box housing as follows:
– Hold one end of circlip with screwdriver -A-.
– Lever other end of circlip out of slot in grooved ball bearing in
direction of -arrow- with 2nd screwdriver -B-.
– Lever circlip out further by repositioning screwdriver -B-.
– Remove gearbox housing/clutch housing securing bolts -A-.
– Screw adapter VW 771/40 into threaded hole in gearbox hous‐

ing.
input shaft ball bearing in gearbox housing for approx. 10 mi‐
nutes to approx. 100°C.
– Using multi-purpose tool VW 771/1 , pull gearbox housing off
clutch housing in direction of -arrow-.
Note
If necessary, carefully apply a lever to the protruding flanges on

alternate sides of the gearbox housing, taking care not to damage
the sealing surfaces.
– Remove splitter -A- and installing sleeve VW 455 from input

shaft.
A second mechanic is required for removing the shafts from the
clutch housing.

– Lift up differential -1- with your left hand. With your right hand,
lift 1st - 4th gear output shaft together with selector rods -2-
-arrow A-.
– At the same time, the second mechanic must lift the input
shaft, reverse shaft and 5th/6th gear output shaft -3- out of the
clutch housing together with the selector rods -arrow B-.
Note
If required, the differential can be put back in the clutch housing

after lifting the shafts.
– Lever out input shaft oil seal using oil seal extractor lever - VW
681- .
Note
Always renew grooved ball bearing on input shaft
⇒ Item 6 (page 126) .
Installing
• A new grooved ball bearing has been pressed onto the input
shaft ⇒ Item 6 (page 126) .
– Insert input shaft -1-, output shaft for 5th and 6th gear -2- to‐
gether with selector rod -3-, selector fork -4- and reverse shaft
-5-.
Observe different mountings of reverse gear selector fork.
Reverse gear selector fork -1- is fitted on shaft -2- behind selector
rod for 5th/6th gear -3-.
– Reverse gear selector fork -1- is fitted on shaft -2- behind se‐
lector rod for 5th/6th gear -3-.

Reverse gear selector fork -1- is fitted on selector rod with selector
fork for 5th/6th gear -2-.
– Reverse gear selector fork -1- is fitted on selector rod with se‐
lector fork for 5th/6th gear -2-.
Continued for all vehicles:

– Then install differential -1-.
Note
A second mechanic is required for installing the shafts in the

clutch housing.
– Take 1st - 4th gear output shaft -3- with selector rods -4- in
your right hand as illustrated.
– Lift differential slightly with your left hand.
– At the same time, have the second mechanic lift the input shaft
and output shaft for 5th, 6th and reverse gear -2- slightly, to‐
gether with the reverse shaft.
– Now insert 1st - 4th gear output shaft in direction of -arrow-.
• The teeth of the input shaft, output shafts and final drive gear/
differential must mesh.
– Now, together with second mechanic, locate shafts and dif‐
ferential in their bearing seats.
– Secure support bridge - 30-211A- for input shaft to clutch

housing.
Note
Illustration shows clutch housing turned through 180° for clarity.
– Screw in bolt -A- until input shaft lifts slightly.

Grooved ball bearing for input shaft will fit into gearbox housing
in one position only.
The grooved ball bearing and the bearing mounting are flattened
on one side.
• If the sides are flattened -A- and -B-, a shim must not be fitted
above or below the grooved ball bearing ⇒ page 130 .
• Flattened sides -A- on grooved ball bearing and bearing
mounting -B- in gearbox housing must be aligned.
– Mark flattened sides with paint.
– Copy markings onto top area of grooved ball bearing and top
area of bearing mounting on gearbox housing (⇒ next illustra‐
tion).
grooved ball bearing for input shaft in gearbox housing for ap‐
prox. 10 minutes to 100°C.
Note
♦ Heating is necessary to ensure that grooved ball bearing is not

damaged when installing gearbox housing.
♦ Apply sealing paste - AMV 188 200 03- evenly to sealing sur‐
face of clutch housing.
♦ Align marking -A- on grooved ball bearing with marking -B- on
gearbox housing and fit gearbox housing.
– Fit gearbox housing and tighten new bolts -A-, -B- and -C- to
specified torque.
Allocation of bolts:

– Install circlip -1- for input shaft grooved ball bearing.

– Attach support bridge - 30 - 211 A- for input shaft.
– If stop sleeve for selector shaft has been removed, drive it in
now ⇒ page 119 (drive in until tool reaches stop).
– Turn gearbox on assembly stand so that opening for selector
shaft faces up.
– Insert selector shaft -1- into bottom mounting -2- and into se‐
lector forks -3-.
Note
The sealing cap is removed to give a better illustration.
– Now push selector shaft -1- against stop sleeve -2- in direction
of -arrow- and run selector finger -3- down through selector
forks and onto stop.
• Selector mechanism cover -4- should be parallel to joint sur‐
face on gearbox housing.
• Selector shaft should move up and down easily (gate selector
movement).
Note
If the selector mechanism cover is not parallel with the joint sur‐
face, the selector shaft is not seated in its bottom mounting.
– Tighten bolts -3- for selector mechanism cover -4-.

– Screw in locking bolt -2-; angled rod -arrow- must be released.
– Install reversing light switch - F4- -1-.
– Install flange shafts together with springs, thrust washers and
tapered rings.

– Drive sealing cap into gearbox housing onto stop.
– Secure sealing cap with circlip -A-.

7 Gearbox housing, clutch housing

⇒ “7.1 Exploded view - gearbox housing”, page 110
⇒ “7.2 Exploded view - clutch housing”, page 112
⇒ “7.3 Servicing gearbox housing”, page 114
⇒ “7.4 Servicing clutch housing”, page 122
7.1 Exploded view - gearbox housing
1 - Gearbox housing
❑ If renewed: Adjust out‐
put shafts and differen‐
tial ⇒ page 182
❑ Modifications in area of
mounting for grooved
ball bearing on input
shaft
parts catalogue
2 - Sealing cap
❑ Driving in ⇒ page 117
3 - Oil drain plug
❑ Tightening torque
⇒ page 111
4 - Seal
❑ If fitted, always renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Oil filler plug with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Tightening torque
⇒ page 111
6 - Angled rod
❑ For adjusting selector
mechanism ⇒ page 45
❑ Can be renewed without
dismantling gearbox
⇒ page 118
7 - Bearing bush
❑ For selector rods
❑ Pulling out ⇒ page 118
8 - Stop sleeve
❑ Pressing out (gearbox dismantled) ⇒ page 119
❑ Driving out (gearbox not dismantled) ⇒ page 119
❑ Identification of different types of stop sleeve ⇒ page 119
❑ Driving in stop sleeve with shoulder ⇒ page 120
❑ Driving in stop sleeve without shoulder ⇒ page 120

9 - Needle bearing
❑ For reverse shaft
❑ Always renew after removing
❑ Pressing in ⇒ page 120
10 - Tapered roller bearing outer race
❑ For 5th/6th and reverse gear output shaft
❑ If renewed: Adjust 5th/6th and reverse gear output shaft ⇒ page 182
11 - Shim
❑ Table of adjustments ⇒ page 182
❑ For 1st - 4th gear output shaft
❑ If renewed: Adjust 1st - 4th gear output shaft ⇒ page 157
13 - Shim
❑ For differential
❑ If renewed: adjust differential ⇒ page 175
15 - Shim
16 - Bearing bush
❑ Driving in ⇒ page 121 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
17 - Sealing plug
❑ Driving out ⇒ page 121
18 - Seal
Different versions of oil filler/oil drain plug

I - Oil filler/ oil drain plug with multi-point socket
• 45 Nm
II - Oil filler/oil drain plug with hexagon socket
• 30 Nm
7. Gearbox housing, clutch housing 111

7.2 Exploded view - clutch housing
1 - Bearing bush
❑ For selector rods
moving
shaft
❑ Installed up to gearbox
manufacturing date
24 05 9 ⇒ page 105
❑ Not installed from gear‐
box manufacturing date
25 05 9 onwards
❑ Reverse gear selector
fork is then mounted to‐
gether with selector fork
for 5th/6th gear
⇒ page 106
❑ Shaft cannot be re‐
moved with workshop
tools
❑ Up to gearbox manufac‐
turing date 24 05 9:
press in new shaft if a
newbyclutch
Protected housing
copyright. isprivate
Copying for fit‐ or commercial purposes, in part or in whole, is not
ted ⇒unless
permitted page 124 by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
parts catalogue
3 - Needle bearing
❑ For reverse shaft
moving
4 - Dowel sleeve
❑ 2x
5 - Clutch housing
❑ If renewed: Adjust output shafts and differential ⇒ page 182
6 - Input shaft oil seal
7 - Oil seal
❑ For flange shaft (right-side)
8 - Shim
❑ Installation position: Shoulder on inside diameter faces towards oil seal ⇒ Item 7 (page 112)

❑ If renewed: adjust differential ⇒ page 175

10 - Oil deflector plate
❑ Installation position: Shoulder on drilling faces towards output shaft
❑ If renewed: Adjust 1st - 4th gear output shaft ⇒ page 157
❑ If renewed: Adjust 5th/6th and reverse gear output shaft ⇒ page 161
13 - Shim
❑ Always 0.65 mm thick
14 - Roller bearing
❑ For input shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ pagewith
127respect to the correctness of information in this document. Copyright by AUDI AG.
15 - Magnet
❑ Held in place by joint surface of housing
16 - Cap
❑ Not fitted on all clutch housings

7.3 Servicing gearbox housing

equipment required
♦ Drift sleeve - VW 244B-
♦ Tube - VW 416 B-
21/2-
21/4-
ko 22/2-

♦ Guide pin - VW 436A-

♦ Guide pin - VW 439-
771-
♦ Guide pin - 10-15-
♦ Thrust piece - 3124-

♦ Punch - 3264-
♦ Assembly tool - 3290-
1331-
♦ Drift - T10168-
♦ Drift - T10169-

♦ Or drift - T10362-
⇒ page 119
♦ -1- Internal puller -

Kukko 21/2-

Kukko 21/4-
♦ -4- Counter-support -
Kukko 22/2-
Removing sealing cap
-A-
– Pierce rubber in cen‐
tre of sealing cap with
a screwdriver -B- and
pry off sealing cap
-in direction of arrow-
.
Driving in sealing cap onto stop

Removing angled rod for selector shaft

– Shear off rod in released position.
– Insert screwdriver -A- in bore for angled rod -B-.
– Lever out angled rod in direction of -arrow-.
Installation position of angled rod

– Marking on angled rod -arrow- must face towards connection
on slave cylinder -1-.
Dimension -a- must be approx. 45°.
Driving in angled rod -arrow- for selector shaft as far as tool stop
Note
Angled rod must be in released position when driving in.
Pulling out bearing bush for selector rod

A - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-

Driving in bearing bush for selector rod (drive in until tool contacts
stop)
Pressing stop sleeve -A- out of gearbox housing

– Place gearbox housing on thrust plates - VW 401- and -VW
402- so that the dowel sleeves in the gearbox housing do not
become damaged.
Driving out stop sleeve (gearbox not dismantled) using guide pin
- 10-15-
• Locking bolt and selector shaft removed
– Turn gearbox so that stop sleeve does not drop into gearbox.
Identification of different types of stop sleeve

The following stop sleeves can be installed:
Stop sleeve with shoulder -arrow 1- ⇒ page 120
Stop sleeve without shoulder -arrow 2- ⇒ page 120
Select correct components from ⇒ Electronic parts catalogue .

Driving in stop sleeve with shoulder as far as tool stop

• Gearbox housing bolted to clutch housing
Driving in stop sleeve without shoulder as far as tool stop

• Gearbox housing bolted to clutch housing
Pulling needle bearing for reverse shaft out of gearbox housing

A - Internal puller 23.5 ... 30 mm , e.g. -Kukko 21/4-
Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing -A- into gearbox housing

– Before pressing in, place reverse shaft thrust washer -A- onto
needle bearing.
– Support gearbox housing with tube - VW 416 B- directly below
bearing mounting.

Pulling out selector shaft bearing bush

– Hold spindle of assembly tool - 3290- tight and turn nut -B-.
A - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-
Driving in bearing bush -A- for selector shaft until flush
Driving out sealing plug -1-

– Drive out plug -1- from inside of gearbox housing -arrow-.

Driving in sealing plug -1-

– Use punch - 3264- to drive in sealing plug to dimension -a- =
approx. 3 mm below top edge of housing.
7.4 Servicing clutch housing

equipment required
♦ Drift - T10168-
21/2-
21/4-
ko 22/2-

Pulling out bearing bush for selector rod

B - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-
Driving in bearing bush for selector rod (drive in until tool contacts
stop)
Pulling needle bearing out of clutch housing

B - Internal
Protected puller 23.5
by copyright. ... 30
Copying for mm
private, or
e.g. -Kukko
commercial 21/4-in part or in whole, is not
purposes,
Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing -A- into clutch housing

– Before pressing in, place reverse shaft thrust washer -B- onto
needle bearing.

Pressing reverse gear selector fork shaft into clutch housing

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Exploded view - input shaft”, page 125
⇒ “1.2 Dismantling and assembling input shaft”, page 127
1.1 Exploded view - input shaft
Note
Lubricate all bearings on input shaft with gear oil before installing.
1 - Circlip
❑ For grooved ball bearing
on input shaft
⇒ page 89
2 - Shim
❑ Outside diameter = 78.6
mm
❑ Can only be fitted on
modified gearbox hous‐
ing (from gearbox man‐
ufacturing date 10 04 6
to 20 01 8) ⇒ page 130
parts catalogue
3 - Gearbox housing
❑ From gearbox manufac‐
turing date 10 04 6 to
20 01 8: modified in area
of seat for grooved ball
bearing
⇒ Item 6 (page 126) to
match shims
⇒ Item 2 (page 125) and
⇒ page 130
❑ From gearbox manufac‐
turing date 21 01 8 on‐
wards, grooved ball
bearing and bearing
seat have flattened
sides ⇒ page 130
parts catalogue
4 - Shim
❑ with
Outside
respect todiameter = of85information
mm in this document. Copyright by AUDI AG.
the correctness
❑ Can only be fitted on modified gearbox housing (from gearbox manufacturing date 10 04 6 to 20 01 8)
⇒ page 130
❑ Select correct components from ⇒ Electronic parts catalogue
1. Input shaft 125

5 - Circlip
❑ When grooved ball bearing ⇒ Item 6 (page 126) or input shaft ⇒ Item 8 (page 126) are renewed: de‐
termine thickness of required circlip ⇒ page 130
6 - Grooved ball bearing
❑ Always renew
❑ Pulling off ⇒ page 128
❑ Installation position ⇒ page 129
❑ Pressing on ⇒ page 129
❑ From gearbox manufacturing date 21 01 8 onwards, grooved ball bearing and bearing seat have flattened
sides ⇒ page 130
7 - 5th gear wheel
❑ Pressing off ⇒ page 129
❑ Installation position: Circular slot -arrow- faces towards grooved ball bearing ⇒ Item 6 (page 126)
8 - Input shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With 3rd/4th and 6th gear wheels permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Roller bearing
❑ With circlip
❑ Installation position: Circlip in bearing faces towards input shaft
10 - Clutch housing
126 Rep. gr.35 - Gears, shafts

1.2 Dismantling and assembling input shaft

equipment required
1. Input shaft 127


♦ Press tool - 30–505-
♦ Thrust plate - 40-105-
♦ Tube - 2040-
21/5-
♦ -2- Puller - Kukko 18/1-
ko 22/2-
Pulling off grooved ball bearing

– First remove circlip from input shaft.
– Before setting up puller, position thrust piece - VW 431- and
thrust plate - 40-105- on input shaft.
– Apply splitter -B- at circular slot for circlip in bearing.
A - Puller , e.g. -Kukko 18/1-
B - Splitter 12...75 mm , e.g. -Kukko 17/1-

Pressing off 5th gear wheel

A - Splitter 22...115 mm , e.g. -Kukko 17/2-
Pressing on 5th gear wheel

Slot -arrow- on gear wheel must face upwards.
Installation position of grooved ball bearing

Slot for circlip faces upwards -arrow A- and shoulder -arrow B-
must face towards 5th gear wheel.
Pressing on grooved ball bearing

Grooved ball bearing with rubber ring -arrow-
Shoulder -A- faces towards press tool - VW 412- .
– Determine thickness of circlip for grooved ball bearing on input
shaft (⇒Protected
next illustration) and fit circlip.
1. Input shaft 129

Determining thickness of circlip for grooved ball bearing on input

shaft
– Install a 1.86 mm thick circlip -A- in slot on input shaft and
press circlip upwards.
– Measure gap between grooved ball bearing -B- and fitted cir‐
clip -A- using feeler gauge -C-.
– Remove circlip fitted for measurement.
– Select circlip from table.
Note
Select circlips from ⇒ Electronic parts catalogue .
The following circlips are available:

Measured value Circlip thickness Axial clearance
(mm) (mm) (mm)
0.01 … 0.05 1.86 0.01 … 0.05
0.05 … 0.07 1.89 0.01 … 0.05
0.07 … 0.10 1.92 0.01 … 0.05
0.10 … 0.13 1.95 0.01 … 0.05
0.13 … 0.16 1.98 0.01 … 0.05
Pulling roller bearing out of clutch housing

– When pulling out, compress circlip -arrow- for roller bearing
using pliers -C-.
Pressing roller bearing into clutch housing

– When pressing in, compress circlip -arrow- for roller bearing
using pliers -A-.
– Remove the pliers before Protected
the roller bearing
by copyright. is inforitsprivate
Copying finalor posi‐
commercial purposes, in part or in whole, is not
tion. The circlip must engagewithinrespect
the groove in the clutch
to the correctness of information in this document. Copyright by AUDI AG.
housing.
Modifications in area of grooved ball bearing
From gearbox manufacturing date 10 04 6 to approx. 20 01 8:
One shim above and one shim below bearing seat for grooved
ball bearing ⇒ Item 6 (page 126) .

Above bearing seat:

Bearing seat Shim above bearing
seat
Up to gearbox man‐ Dimension “a” = 10 No
ufacturing date mm
09 04 6
From gearbox man‐ Dimension “a” = Yes
ufacturing date 10.7 mm
10 04 6
to 20 01 8
Gearboxes manu‐ Below bearing seat: No
factured from Flattened side for
21 01 8 onwards grooved ball bearing
Below bearing seat -arrow-:
From gearbox manufacturing date 10 04 6 to approx. 20 01 8

slightly deeper
Bearing seat for grooved ball bearing -arrow- is slightly deeper to
accommodate the shim below the bearing ⇒ Item 6 (page 126) .
Below bearing seat Shim below bearing
seat
Up to gearbox man‐ Not modified No
ufacturing date
09 04 6
From gearbox man‐ Slightly deeper Yes
ufacturing date
10 04 6
to 20 01 8
Gearboxes manu‐ Flattened side -B- No
factured from for grooved ball
21 01 8 onwards bearing -A-
From gearbox manufacturing date 21 01 8 onwards, grooved ball

bearing -A- and bearing seat -B- in gearbox housing have flat‐
tened sides.
• If sides are flattened, a shim must not be fitted above or below
grooved ball bearing.
1. Input shaft 131

2 Output shaft
⇒ “2.1 Exploded view - output shaft”, page 132
⇒ “2.2 Dismantling and assembling output shaft”, page 137
⇒ “2.3 Adjusting output shaft”, page 157
2.1 Exploded view - output shaft

⇒ “2.1.1 Exploded view - output shaft for 1st - 4th gear”,
page 132
⇒ “2.1.2 Exploded view - output shaft for 5th, 6th and reverse
gear”, page 135
2.1.1 Exploded view - output shaft for 1st - 4th gear
Note
♦ Carry out output

Protected shaft
by copyright. adjustment
Copying ⇒ page purposes,
for private or commercial 157 if the output
in part shaft
or in whole, is notor tapered roller bearings have been
renewed.
♦ Always renew both tapered roller bearings together.
1 - Clutch housing
2 - Oil deflector plate
3 - Dished washer
❑ Pressing in
⇒ page 141
4 - Tapered roller bearing outer
race
❑ Pressing in
⇒ page 142
5 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 143
❑ Pressing on
⇒ page 143
6 - Output shaft
❑ For 1st to 4th gear
7 - Needle bearing
❑ For 2nd gear
8 - 2nd speed selector gear
9 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Checking for wear
⇒ page 143
❑ Check lugs for scoring
⇒ page 144

10 - Outer ring for 2nd gear

❑ Fit on synchro-ring ⇒ Item 9 (page 132)
❑ Renew if scored or if there are visible traces of wear
11 - 2nd gear synchro-ring
❑ Checking for wear ⇒ page 143
12 - Locking collar with synchro-hub for 1st and 2nd gear
❑ Press off together with 2nd speed selector gear after removing circlip ⇒ Item 13 (page 133)
⇒ page 142
❑ Dismantling ⇒ page 144
❑ Assembling locking collar/synchro-hub ⇒ page 144
13 - Circlip
14 - 1st gear synchro-ring
❑ Assemble so that the recesses engage on the locking pieces on the locking collar
15 - Outer ring for 1st gear
❑ Insert in synchro-ring ⇒ Item 14 (page 133) ; installation position ⇒ page 145
16 - Synchro-ring
❑ (Inner ring for 1st gear)
17 - Needle bearing
❑ For 1st gear
18 - 1st speed selector gear
19 - Thrust washers
❑ For 1st and 4th gear
❑ 2x
❑ Insert lug on thrust washer in hole on output shaft
20 - Securing clip
❑ Holds thrust washers ⇒ Item 19 (page 133) in position on output shaft
21 - Needle bearing
❑ For 4th gear
23 - 4th gear synchro-ring
24 - Locking collar with synchro-hub
permitted unless authorised byfor
AUDI3rdAG.and
AUDI4th gear
AG does not guarantee or accept any liability
❑ Pull off together with 4th speed selector gear after removing circlip ⇒ Item 25 (page 134) ⇒ page 142

❑ Installation position: Locking collar/synchro-hub ⇒ page 146
❑ Assembling locking collar/synchro-hub ⇒ page 144 and ⇒ page 144
2. Output shaft 133


25 - Circlip
26 - 3rd gear synchro-ring
27 - Outer ring for 3rd gear
❑ Insert in synchro-ring ⇒ Item 26 (page 134) ; installation position ⇒ page 145
28 - Synchro-ring
❑ (Inner ring for 3rd gear)
29 - Needle bearing
❑ For 3rd gear
30 - 3rd speed selector gear
31 - Tapered roller bearing inner race
32 - Circlip
❑ When tapered roller bearing ⇒ Item 31 (page 134) or output shaft ⇒ Item 6 (page 132) are renewed:
determine thickness of required circlip ⇒ page 147
34 - Shim
❑ Determining thickness ⇒ page 157

2.1.2 Exploded view - output shaft for 5th, 6th and reverse gear
Note
♦ Carry out output shaft adjustment ⇒ page 161 if the output shaft or tapered roller bearings have been
renewed.
1 - Clutch housing
2 - Shim
race
❑ Pressing in
⇒ page 152
race
❑ Pressing on
⇒ page 156
5 - Output shaft
❑ For 5th, 6th and reverse
gears
6 - Reverse gear synchro-hub
❑ Pressing off
⇒ page 153
⇒ page 154
❑ Pressing on
⇒ page 154
7 - Circlip
8 - Reverse gear locking collar
❑ With synchro-ring
9 - Needle bearing
❑ For reverse selector
gear
10 - Reverse selector gear
11 - Sleeve
❑ Press off with reverse selector gear ⇒ page 153
❑ Installation position: Wide shoulder of sleeve faces towards reverse selector gear
❑ authorised
Pressing on ⇒ AG.page 154
permitted unless by AUDI AUDI AG does not guarantee or accept any liability
12 - Circlip
13 - Needle bearing
❑ For 6th gear
2. Output shaft 135

16 - Locking collar with synchro-hub for 5th and 6th gear

❑ Press off together with 6th speed selector gear after removing circlip ⇒ Item 17 (page 136)
⇒ page 153
❑ Assembling locking collar/synchro-hub ⇒ page 155 and ⇒ page 155
17 - Circlip
18 - Needle bearing
❑ For 5th gear
21 - Tapered roller bearing inner race
❑Protected
Pressing on ⇒Copying
by copyright. pagefor156
private or commercial purposes, in part or in whole, is not
22 - Circlip
❑ When tapered roller bearing ⇒ Item 21 (page 136) or output shaft ⇒ Item 5 (page 135) are renewed:
determine thickness of required circlip ⇒ page 156
24 - Shim
❑ Determining thickness ⇒ page 161
26 - Spring
27 - Locking collar
28 - Synchro-hub
29 - Locking pieces (3x)

2.2 Dismantling and assembling output

shaft
⇒ “2.2.1 Dismantling and assembling output shaft for 1st - 4th
gear”, page 137
⇒ “2.2.2 Dismantling and assembling output shaft for 5th, 6th and
reverse gear”, page 147
2.2.1 Dismantling and assembling output shaft for 1st - 4th gear

equipment required
♦ Press tool - VW 408A-
♦ Tube - VW 415 A-
2. Output shaft 137



♦ Thrust pad - VW 512-

♦ Tube - VW 516-
♦ Tube - VW 519-
771-
2. Output shaft 139

♦ Drift sleeve - 40-20-

♦ Press tool - 40-21-
♦ Engine and gearbox sup‐
port supplement - VW
540/1 B-
♦ Tapered roller bearing pull‐
er - V.A.G 1582-
♦ Adapter - V.A.G 1582/7-


Kukko 21/7-

Kukko 21/8-
♦ -2- Puller - Kukko
18/2-
♦ -3- Splitter - Kukko
17/2-
Kukko 22/2-
Pulling dished washer
-A- out of output shaft
Pressing dished washer into output shaft

Dimension “a” = 2 mm
Pulling out tapered roller bearing outer race

2. Output shaft 141

Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with drift sleeve - 40-20- directly below
bearing mounting.
Pulling off tapered roller bearing inner race

– First remove circlip.
– Before applying puller, fit press tool - VW 431- in output shaft
and place thrust plate - 40-105- on it.
Pulling off 3rd and 4th gear synchro-hub/locking collar with 4th
speed selector gear
A - Puller , e.g. -Kukko 18/2-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
B - Splitter 22...115 mm , e.g. -Kukko 17/2-
Pressing off 1st and 2nd gear locking collar and synchro-hub
After removing the circlip, press off 2nd speed selector gear and
locking collar/synchro-hub together.

Pressing off tapered roller bearing inner race

Pressing on tapered roller bearing inner race
Checking inner ring for 1st, 2nd and 3rd gear for wear
– Press inner ring onto cone on selector gear and measure gap
-a- using a feeler gauge.
Gap -a- Installation depth Wear limit
1st, 2nd and 3rd 0.75…1.25 mm 0.3 mm
gear
Checking 1st, 2nd and 3rd gear synchro-rings for wear

– Press synchro-ring, outer ring and inner ring onto cone on se‐
lector gear and measure gap -a- using a feeler gauge.
1st, 2nd and 3rd 1.2…1.8 mm 0.5 mm
gear
2. Output shaft 143

Installation position of outer ring, inner ring and synchro-ring of

2nd gear
– Place inner ring -A- on 2nd speed selector gear.
The angled lugs -arrows 1- point towards outer ring -B-.
– Fit outer ring -B-.
The lugs -arrows 2- lock in the slots -arrows 3- on the selector
gear.
– Fit synchro-ring -C-.
The slots -arrows 4- locate on the lugs -arrows 1- of inner ring
-A-.
Dismantling and assembling 1st/2nd gear and 3rd/4th gear lock‐

ing collar/synchro-hub
1- Spring
2- Locking piece
3- Locking collar
4- Synchro-hub
– Slide locking collar over synchro-hub.
Recesses for locking pieces in synchro-hub and locking collar
must align.
Assembling 1st/2nd gear and 3rd/4th gear locking collar/synchro-

hub
Locking collar is pushed over synchro-hub.
– Insert locking pieces and install springs offset at 120°. Angled
end of spring must locate in hollow locking piece.
Installation position of 1st and 2nd gear locking collar/synchro-

hub
Identification groove -arrow 1- and narrow shoulder -arrow 2- on
synchro-hub point towards 1st gear.

Pressing on 1st and 2nd gear locking collar/synchro-hub

– Fit circlip.
Installation position of 1st or 3rd gear outer ring

Lugs -arrows- face towards synchro-hub/locking collar -A-.
Installation position of synchro-ring -A- (inner ring for 1st or 3rd

gear)
Lugs -arrows 1- locate in the recesses -arrows 2- in the synchro-
ring -B-.
Installation position of 1st and 3rd speed selector gear

The higher shoulder -A- faces towards 2nd or 4th gear -B-. The
recesses in the shoulder -arrows- engage on the lugs on the outer
ring ⇒ page 145 .
2. Output shaft 145

Installation position of 3rd and 4th gear locking collar/synchro-hub

The wider shoulder on the synchro-hub -arrow- faces towards 3rd
gear.
Pressing on 3rd and 4th gear synchro-hub with locking collar
– Fit circlip.
Checking 4th gear synchro-ring for wear

– Press synchro-ring onto cone on selector gear and measure
gap -a- with a feeler gauge.
4th gear 1.0…1.7 mm 0.5 mm

– Determine thickness of required circlip ⇒ page 147 and install
circlip.

Determining thickness of circlip

– Determine the thickest circlip that will just fit and install it.
Note
Select circlips from ⇒ Electronic parts catalogue .
The following circlips are available:

Thickness (mm)
1.79 1.83 1.86 1.89
1.92 1.95 1.98
Pulling tapered roller bearing outer race out of gearbox housing

Pressing tapered permitted
roller bearing outerbyrace
unless authorised into
AUDI AG. gearbox
AUDI housing
AG does not guarantee or accept any liability
– Fit shim below outer race.
– Support gearbox housing with thrust piece - 2050- directly be‐
low bearing mounting.
2.2.2 Dismantling and assembling output shaft for 5th, 6th and reverse gear
2. Output shaft 147


equipment required
♦ Press tool - VW 408A-
♦ Tube - VW 415A-


♦ Support rails - VW 457-
2. Output shaft 149


♦ Thrust pad - VW 510-
♦ Tube - VW 516-
♦ Tube - VW 519-


♦ Drift sleeve - 40-20-
♦ Tube - 3296-
er - V.A.G 1582-
♦ Adapter - V.A.G 1582/4-
2. Output shaft 151

♦ Adapter - V.A.G
1582/7-

Kukko 21/7-
♦ -3- Splitter - Kukko

17/2-
Kukko 22/2-
Pulling out tapered roller
bearing outer race
A - Counter-support ,
e.g. -Kukko 22/2-
B - Internal puller 46...58
mm , e.g. -Kukko 21/7-
Note
After pulling out, check

shim for damage and re‐
new if necessary.

– Fit shim below outer race.
– Support clutch housing with drift sleeve - 40-20- directly below
bearing mounting.


– Before setting up puller, position thrust piece - VW 431- and
thrust plate - 40-105- on output shaft.
Pressing off 5th and 6th gear synchro-hub/locking collar with 6th
speed selector gear
Pressing off sleeve -A- with reverse selector gear

Pressing off reverse gear synchro-hub

2. Output shaft 153


– Before applying puller, place thrust plate - 30-11- on output
shaft.
Installation position of reverse gear synchro-hub

Stop -arrow A- for reverse gear locking collar faces towards gear
teeth on output shaft -arrow B-.
Pressing on reverse gear synchro-hub

– Fit circlip.
Pressing on sleeve -A-

Installation position: Wide shoulder faces towards reverse selec‐
tor gear
– Fit circlip.

Checking 5th and 6th gear synchro-ring for wear

– Press synchro-ring onto cone on selector gear and measure
gap -a- with a feeler gauge.
5th and 6th gear 1.0…1.7 mm 0.5 mm
Dismantling and assembling 5th and 6th gear locking collar and
synchro-hub
1- Spring
2- Locking piece
3- Locking collar
4- Synchro-hub
– Slide locking collar over synchro-hub.
Recesses for locking pieces in synchro-hub and locking collar
must align.
Assembling 5th and 6th gear locking collar/synchro-hub

Locking collar is pushed over synchro-hub.
– Insertpermitted
locking pieces
unless andby install
authorised AUDI AG.springs offset
AUDI AG does at 120°.or Angled
not guarantee accept any liability
end of spring must locate in hollow locking piece.

Pressing on 5th and 6th gear locking collar/synchro-hub

On some versions the outer diameter of the locking collar is
chamfered.
Installation position: Chamfer on outer diameter of locking collar
faces towards 5th speed selector gear.
– Fit circlip.
2. Output shaft 155


– Determine thickness of required circlip ⇒ page 156 and install
circlip.
Determining thickness of circlip

– Determine the thickest circlip that will just fit and install it. by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
– Select circlip from table. For part numbers, refer to ⇒ Elec‐
Circlips available
Thickness (mm)
1.79 1.89 1.98
1.83 1.92
1.86 1.95

B - Internal puller 46...58 mm , e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with thrust piece - 2050- directly be‐
low bearing mounting.
2.3 Adjusting output shaft

⇒ “2.3.1 Adjusting output shaft for 1st - 4th gear”, page 157
⇒ “2.3.2 Adjusting output shaft for 5th, 6th and reverse gear”,
page 161
2.3.1 Adjusting output shaft for 1st - 4th gear

(Determining thickness of output shaft shim)
The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 1st - 4th gear, or
♦ Tapered roller bearing for output shaft
Table of adjustments ⇒ page 182
2. Output shaft 157


equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Assembly device - VW 792-


1331-
21/7-
ko 22/2-
Requirements:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
• When taking measurements, install only the output shaft that
is to be measured.
– Press tapered roller bearing outer race with shim (thickness
1.70 mm) into gearbox housing. Support gearbox housing with
thrust piece - 2050- directly below bearing mounting.
– Fit complete 1st to 4th gear output shaft into clutch housing.
2. Output shaft 159

– Fit gearbox housing and tighten bolts -A- and -B- diagonally to
correct torque.
– Set up measuring tools and secure with bolt -arrow- to clutch

housing.
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐
load.
– Loosen clutch housing/gearbox housing securing bolts diag‐
onally until output shaft is free to move in gearbox housing.
– Read off play on gauge and note reading (example: 0.14 mm).
Note
If no play is indicated on dial gauge when clutch housing/gearbox

housing securing bolts are loosened, fit a 1.95 mm shim (or if
necessary a 2.20 mm shim) ⇒ Electronic parts catalogue for per‐
forming the measurement.
Determining thickness of shim

The specified bearing preload is attained by subtracting the meas‐
ured value (0.14 mm) from the inserted shim (1.70 mm) and
adding a constant value for preload (0.20 mm).
Example:
Inserted shim Protected by copyright. Copying1.70 mm
for private or commercial purposes, in part or in whole, is not
– Measured value 0.14
with respect to the correctness mm in this document. Copyright by AUDI AG.
of information
+ Preload (constant value) 0.20 mm
Thickness of shim 1.76 mm
– Determine thickness of shim from table ⇒ page 161 .

– Detach gearbox housing and pull tapered roller bearing outer

race out of gearbox housing.
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.45 1.75 2.05
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
thickness required.
– Determine part number of shim from ⇒ Electronic parts cata‐
logue .
– Press
permitted unlessin tapered
authorised roller
by AUDI AG.bearing
AUDI AG doesouter race together
not guarantee with
or accept any the
liability
withcorrect
respect to shim (in example
the correctness 1.75
of information mm).
in this Support
document. gearbox
Copyright by AUDI AG. housing
with thrust piece - 2050- directly below bearing mounting.
Checking adjustment
• Required shim installed (thickness as determined above)
– Set up measuring tools and secure with bolt -arrow- to clutch

housing.
load.
– If the correct shim has been selected, the dial gauge should
now indicate a value between 0.15 and 0.25 mm.
2.3.2 Adjusting output shaft for 5th, 6th and

reverse gear
The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 5th, 6th and reverse gears, or
♦ Tapered roller bearing for output shaft
2. Output shaft 161


equipment required
et - VW 387-
♦ Assembly tool - VW 792-


1331-
21/7-
ko 22/2-
Requirements:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
• When taking measurements, install only the output shaft that
is to be measured.
– Press tapered roller bearing outer race with shim (thickness
1.70 mm) into gearbox housing. Support gearbox housing with
thrust piece - 2050- directly below bearing mounting.
– Insert complete 5th, 6th and
Protected reverse
by copyright. gearforoutput
Copying private orshaft in clutch
commercial purposes, in part or in whole, is not
housing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2. Output shaft 163

– Fit gearbox housing and tighten bolts -A- and -B- diagonally to
correct torque.
– Attach measuring equipment. Put washers of a total thickness

of 8 mm on boltProtected
-arrow- securing assembly device - VW 792-
to clutch housing.with respect to the correctness of information in this document. Copyright by AUDI AG.
load.
– Read off play on gauge and note reading (example: 0.25 mm).
Note
♦ If no play is indicated on dial gauge when clutch housing/gear‐

box housing securing bolts are loosened, fit a 1.95 mm shim
(or if necessary a 2.20 mm shim) for performing the measure‐
ment.
♦ Select correct shims from ⇒ Electronic parts catalogue .

The specified bearing preload is attained by subtracting the meas‐
ured value (0.25 mm) from the inserted shim (1.70 mm) and
adding a constant value for preload (0.20 mm).
Example:
Inserted shim 1.70 mm
– Measured value 0.25 mm
Thickness of shim 1.65 mm
– Determine thickness of shim from table ⇒ page 165 .

– Detach gearbox housing and pull tapered roller bearing outer

race out of gearbox housing.
B - Internal puller 46...58 mm , e.g. -Kukko 21/7-
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
1.75 2.05
– For part numbers, refer to ⇒ Electronic parts catalogue .
Tolerance variations make it possible to obtain the permitted
exact shim
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
thickness required. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press in tapered roller bearing outer race together with the

correct shim (in example 1.65 mm). Support gearbox housing
with thrust piece - 2050- directly below bearing mounting.
Checking adjustment
• Required shim installed (thickness as determined above)
– Attach measuring equipment. Put washers of a total thickness

of 8 mm on bolt -arrow- securing assembly device - VW 792-
to clutch housing.
load.
– If the correct shim has been selected, the dial gauge should
now indicate a value between 0.15 and 0.25 mm.
2. Output shaft 165

39 – Final drive - front differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - oil seals”, page 166
⇒ “1.2 Renewing oil seal (left-side)”, page 166
⇒ “1.3 Renewing oil seal (right-side)”, page 168
1.1 Overview of fitting locations - oil seals
1 - Oil seal
❑ For input shaft
2 - Oil seal
❑ For flange shaft (right-
side)
3 - Oil seal
❑ For flange shaft (left-
side)
4 - Oil seal
❑ Renewing ⇒ page 84 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.2 Renewing oil seal (left-side)

166 Rep. gr.39 - Final drive - front differential

♦ Multi-purpose tool - VW 771- with puller hook -VW 771/37-
♦ Sealing grease - G 052 128 A1- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Procedure
– Remove flange shaft (left-side) ⇒ page 179 .

– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and puller hook -VW 771/37- .
– Clean contact surface and sealing surface.

1. Oil seals 167

– Drive in oil seal onto stop using thrust piece - 3305- . Take care
to keep seal straight when installing.
– Install flange shaft (left-side) ⇒ page 179 .
⇒ page 76 .
1.3 Renewing oil seal (right-side)


♦ Drift sleeve - 3158-
♦ Extractor tool - T20143-
♦ Sealing grease - G 052 128 A1-

Procedure
– Remove flange shaft (right-side) ⇒ page 180 .
– Use extractor tool -T20143/2- to pull out flange shaft oil seal.
– Clean contact surface and sealing surface.

– Drive in oil seal onto stop using drift sleeve - 3158- . Take care
to keep seal straight when installing.
– Install flange shaft (right-side) ⇒ page 180 .
⇒ page 76 .
1. Oil seals 169

2 Differential
⇒ “2.1 Exploded view - differential”, page 170
⇒ “2.2 Dismantling and assembling differential”, page 172
⇒ “2.3 Adjusting differential”, page 175
⇒ “2.4 Removing and installing flange shaft (left-side)”,
page 179
⇒ “2.5 Removing and installing flange shaft (right-side)”,
page 180
2.1 Exploded view - differential

Note
♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Adjust differential if tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed
⇒ page 175 .
1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 175
race
❑ Pressing in
⇒ page 175
race
❑ Pressing on
⇒ page 174
5 - Differential cage
❑ With riveted final drive
gear
race
❑ Pressing on
⇒ page 174
race
❑ Pressing in
⇒ page 174
8 - Shim
❑ Installation position:
Shoulder on inside diameter faces towards oil seal ⇒ Item 10 (page 171)

9 - Clutch housing
10 - Oil seal
❑ For flange shaft (right-side)
❑ Different diameters for left and right
❑ Renewing with gearbox installed ⇒ page 168
❑ 33 Nm
❑ Screws into threaded piece ⇒ Item 22 (page 171)
12 - Flange shaft (right-side)
❑ Do not interchange; left and right flange shafts are different
13 - Protective ring
❑ Protects
Protected flange
by copyright. Copyingshaft oil seal
for private against
or commercial dirt in part or in whole, is not
purposes,
❑withPrise off on alternate sides using a screwdriver

❑ Installation position: Recess faces away from tapped holes in flange shaft
❑ Press on by hand as far as stop
❑ Must engage in flange shaft
14 - Spring for flange shaft
❑ Installed behind flange shaft
15 - Thrust washer
❑ Installation position: Shoulder towards spring, lugs towards tapered ring
16 - Tapered ring
❑ With grooves to engage on thrust washer
❑ Installation position: Taper towards differential cage
17 - Circlip
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - Sun wheel
19 - Differential pinion pin
❑ Drive out with drift
20 - Spring pin
❑ For securing differential pinion pin
21 - Planet pinion
22 - Threaded piece
23 - One-piece thrust washer
❑ Lubricate with gear oil before installing
24 - Flange shaft (left-side)
❑ Do not interchange; left and right flange shafts are different
25 - Oil seal
❑ For flange shaft (left-side)
❑ Different diameters for left and right
❑ Renewing with gearbox installed ⇒ page 166
2. Differential 171
2.2 Dismantling and assembling differential

equipment required
♦ Press tool - VW 408 A-
♦ Thrust plate - 3005-

♦ Tube - 3259-
♦ Tube - 3296-
♦ Tube - 3345-
er - V.A.G 1582-
♦ Adapter - V.A.G 1582/6A-
21/7-
♦ -2- Puller - Kukko 18/1-
ko 22/2-
Pulling tapered roller bearing outer race out of clutch housing

Note
After pulling out, check shim for damage and renew if necessary.
2. Differential 173

– First install shim.
Note
Observe installation position of shim; shoulder on inner diameter

faces seal.
Pulling off tapered roller bearing inner races

– Before applying puller, place thrust plate - 40-105- on differ‐
ential cage.
Note
The procedure for pulling the tapered roller bearing inner races
off the differential cage is the same for both bearings.
Pressing on tapered roller bearing inner races
Note
The same tools are used for pressing on the tapered roller bearing
inner races for the gearbox housing and clutch housing.


Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with tube - 3345- directly below
bearing mounting.
Removing and installing spring pin for differential pinion pin

Removing
– Cover tapered roller bearing inner race to avoid possible dam‐
age and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into annular
groove.
Installing
– Drive fully into differential cage.
Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Fit planet pinions (180° apart) and pivot into position.
– Push differential pinion pin -arrow A- in as far as first planet
pinion.
– Fit threaded pieces -arrows B- in sun wheels.
Installation position: Stepped shoulder towards sun wheel
– Drive differential pinion pin into final position and secure with
spring pin.
2.3 Adjusting differential

The differential has to be readjusted when the following compo‐
nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage, or
♦ Tapered roller bearings for differential
2. Differential 175

equipment required
♦ End measuring plate -
VW 385/17-
et - VW 387-
♦ Press tool - VW 408 A-
♦ Thrust plate
Protected - 3005-

♦ Tube - 3259-
♦ Tube - 3345-
1331-
♦ -1- Internal puller 46 ... 58
mm - Kukko 21/7-
ko 22/2-
– Press tapered roller bearing outer race with shimbyinto

Protected clutch
copyright. Copying for private or commercial purposes, in part or in whole, is not
housing ⇒ page 173 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Observe installation position of shim; shoulder on inner diameter

faces seal.
2. Differential 177
– Press tapered roller bearing outer race without shim into the
gearbox housing
– Install differential in clutch housing.
– Fit gearbox housing and tighten 5 bolts to specified torque
⇒ Item 11 (page 80) and ⇒ Item 12 (page 80) .
– Press differential towards clutch housing; hold in this position
and turn eight times.
– Press differential towards gearbox housing; hold in this posi‐
tion and turn eight times.
– Attach dial gauge and set to “0” with a preload of 1 mm.

A - Dial gauge extension, 30 mm
– Move differential up and down and note play indicated on dial
gauge (in this example: 0.70 mm).
The specified bearing preload is obtained by adding a constant
figure (0.25 mm) to the reading indicated.
Example:
Measured value 0.70 mm
Thickness of shim = 0.95 mm
– Take off gearbox housing.
– Pull tapered roller bearing outer race out of gearbox housing.

– Determine part number of shim from ⇒ Electronic parts cata‐
logue .
– Install shims of the calculated thickness, thickest shim first.
TheProtected
following shims are available:
Shim thickness (mm)
0.65 0.85 1.05 1.25
0.70 0.90 1.10
0.75 0.95 1.15
0.80 1.00 1.20
If the size of the shim required is larger than those listed in the
table, install two shims amounting to the correct value. Insert the
thicker shim first.
thickness required.

– Press outer race in again and tighten gearbox housing to

specified torque ⇒ Item 11 (page 80) and
⇒ Item 12 (page 80) .
2.4 Removing and installing flange shaft

(left-side)
♦ Hook -2024 A /1-
Removing
• Gearbox in vehicle
insulation .
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (front) .
– Unbolt drive shaft (left-side) from flange shaft of gearbox ⇒

– Remove nuts -arrows- securing swivel joint (left-side).
– If fitted, unscrew nut on bracket for front left vehicle level send‐
er - G78- .
– Disengage swivel joint (left-side) from wishbone.
2. Differential 179
– Swivel suspension strut (left-side) outwards and support with

hook -2024 A /1- as shown in illustration.
WARNING
Risk of accident if parts of support are not properly secured.

♦ Secure locking pin and swivel joint with retaining clip
-arrow- and nut -1-.
– Tie up drive shaft (left-side).
Note
Make sure you do not damage surface coating on drive shaft.
– Remove bolt -arrow- securing flange shaft (left-side). To do so,

screw two bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.
Installing
Installation isunless
permitted carried out in
authorised by reverse sequence;
AUDI AG. AUDI AG does notnote theorfollowing:
guarantee accept any liability
– Push flange shaft in against spring pressure and secure with
bolt.
Tightening torques
♦ ⇒ Item 11 (page 171)
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower wish‐
bone, swivel joint; Exploded view - lower wishbone, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Exploded view - wheel housing liner (front)
2.5 Removing and installing flange shaft

(right-side)
Removing
• Gearbox in vehicle
insulation .

– If fitted, remove bolts -arrows- and detach heat shield for drive
shaft (right-side).
– Unbolt drive shaft (right-side) from flange shaft of gearbox ⇒
– Tie up drive shaft (right-side).
Note
Make sure you do not damage surface coating on drive shaft.
– Remove bolt -arrow- securing flange shaft (right-side). To do

so, screw 2 bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.
Installing
– Push flange shaft in against spring pressure and secure with
bolt.
Tightening torques
♦ ⇒ Item 11 (page 171)
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft
2. Differential 181
3 Table of adjustments
Note
If repairs have been carried out on the gearbox, it is only neces‐

sary to adjust the output shaft for 1st - 4th gear, the output shaft
for 5th, 6th and reverse gear or the differential if components have
been renewed which have a direct effect on the adjustment of the
gearbox. Refer to the following table to avoid unnecessary ad‐
justment work:
Components requiring adjustment:

Output shaft Output shaft Differential
for 1st - 4th for 5th, 6th ⇒ page 175
gear and reverse
⇒ page 157 gears
⇒ page 161
Components renewed: Gearbox housing x x x
Clutch housing x x x
Output shaft for 1st - 4th gear x
Output shaft for 5th, 6th and reverse x
gears
Differential cage x
Tapered roller bearing for 1st - 4th x
gear output shaft
Tapered roller bearing for 5th/6th x
and reverse gear output shaft
Tapered roller bearings for differen‐ x
tial

6 Box - 0a8 Front Wheel Drive

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Service

6-speed manual gearbox 0A8, front-wheel drive

Service Department. Technical Information

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Copyright © 2015 Audi AG, Ingolstadt D3E804022FF

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.1 Gearbox identification

Manual gearbox 0A8 -arrow 2-

Code letters and production date of gearbox -arrow-

2.1 Allocation of gearbox to engine

Manual gearbox 6-speed 0A8 (front-wheel drive)

2 Rep. gr.00 - Technical data

2.3 Calculating gear ratios

6-speed manual 6th gear Final drive

i = Z2 : Z1 Z1 = number of teeth on driving gear,

3.1 Transmission layout - front-wheel drive

4 Rep. gr.00 - Technical data

4.1 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

6 Rep. gr.00 - Technical data

5.1 General repair instructions

Manual ⇒ Workshop equipment and special tools .

Oil seals, seals, O-rings and gaskets

8 Rep. gr.00 - Technical data

♦ Do not interchange synchro-rings. When reusing always fit to

♦ Abnormal wear on synchro-ring or selector gear:

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

10 Rep. gr.00 - Technical data

♦ Abnormal wear on locking collar:

♦ In comparison: intact locking collar:

♦ We recommend the use of accessories approved by Audi.

12 Rep. gr.00 - Technical data

6.1 Overview of fitting locations - electrical

Gearbox neutral position sender - G701- and reversing light

14 Rep. gr.30 - Clutch

Removing retaining clip

Pressing on retaining clip

16 Rep. gr.30 - Clutch

1.2 Exploded view - clutch hydraulics

1.2.1 Exploded view - clutch hydraulics, LHD vehicles

1 - Clutch slave cylinder with

pipe, pull out retaining

❑ Lubricate with brake fluid before installing

1.2.2 Exploded view - clutch hydraulics, RHD vehicles

1 - Clutch slave cylinder with

❑ Lubricate with brake flu‐

18 Rep. gr.30 - Clutch

❑ Lubricate with brake fluid before installing

1.3 Exploded view - clutch release mechanism

1 - Clutch slave cylinder with

1.4 Removing and installing clutch pedal

If the over-centre spring is being removed on its own, the clutch

Special tools and workshop equipment required

– Remove dash panel cover (driver side) ⇒ General body re‐

20 Rep. gr.30 - Clutch

♦ Retainers -A- will be destroyed when you do this.

mounting on clutch pedal -3-.

– Working sideways from below, insert over-centre spring into