Disassembling and assembling sequence Audi A4 B7

Disassembling and assembling sequence

Removing and installing ball bearing for input shaft, end cover, Torsen differential, transmission cover, selector shaft and bearing housing with input shaft and pinion shaft/hollow shaft.

Scheme 519

Special tools, testers and auxiliary items required

1. Drift sleeve VW 244 B
2. Thrust plate VW 401
3. Thrust plate VW 402
4. Thrust disc VW 412

1. Tube 60 mm dia. VW 415 A
2. Thrust pad con. 8/65 VW 433

Scheme 520

Special tools, testers and auxiliary items required

1. Sleeve VW 519
2. Holding fixture VW 540
3. Extension 30 - 23
4. Press tool 40 - 21

1. Sleeve 40 - 103
2. Thrust piece 40 - 105

Scheme 521

Special tools, testers and auxiliary items required

1. Drift sleeve 41 - 501
2. Transmission holder 2004
3. Lock pin 2064
4. Thrust piece 3002

1. Replacement stud (M8 and M10) 3114/2
2. Wheel bearing assembly set 3253

Scheme 522

Special tools, testers and auxiliary items required

1. Workshop press V.A.G 1290 A
2. Drip tray V.A.G 1306
3. Torque wrench V.A.G 1331
4. Torque wrench V.A.G 1332

1. Taper roller bearing puller V.A.G 1582
2. Adapter V.A.G 1582/12
3. 1 - Internal puller Kukko 21/2
4. 2 - Puller Kukko 18/2

Special tools, testers and auxiliary items required

Scheme 523

1. 1 - Two-arm puller Kukko 20/10
2. 2 - Puller hook, length 200 mm
3. 2 - Puller hook, length 250 mm
4. Fitting tool T10246

1. Holding plate T40086
2. Holding plate T40088/1
3. Sleeve T40088/2
4. Feeler gauge

1. 2 bolts M8 (length 70 mm) with washers
2. Sealing paste AMV 188 001 02
3. Assembly sleeve 01E311120
4. Locking fluid AMV185101A1

Scheme 524

1. Mount transmission on assembly stand.
2. Place drip tray V.A.G 1306 under transmission.
3. Drain gear oil.

Scheme 525

1. Remove clutch release lever - A - together with release bearing.
2. Remove guide sleeve - B
3. Remove dished spring - C -.
4. Then remove circlip - D - in front of ball bearing for input shaft.

1. If input shaft or transmission housing is not to be replaced, note thickness of circlip.

Scheme 526

1. Pull input shaft ball bearing out of transmission housing.

Scheme 527

1. Remove circlip - arrow - behind ball bearing for input shaft.
2. If input shaft or transmission housing is not to be replaced, note the thickness of circlip.

Scheme 528

1. Remove bolts - arrows - and detach Torsen housing - A -.

Note. The illustration shows only 4 of the 6 securing bolts.

1. Remove Torsen differential and spring from pinion shaft/hollow shaft.

Scheme 529

1. Remove bolts - arrows - and remove selector shaft cover - A -.

Scheme 530

1. Remove two locking bolts - 1 - for selector shaft.

1. Make sure gear has not been engaged.

1. Push selector shaft - 2 - into transmission as far as it will go, simultaneously removing pin - 3 -.
2. Pull out selector shaft.

Scheme 531

1. Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).

Scheme 532

1. Remove bolts securing transmission cover - A - and bolts securing bearing housing - B - to transmission housing - C -.
2. Carefully remove transmission cover toward rear. The bearing housing remains installed to transmission housing.

Note. Always replace transmission cover O-ring - arrow -.

Scheme 533

1. Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm) and washers.
2. Tighten two bolts to max. 10 Nm.
3. Remove oil collector - A -.

Scheme 534

1. Remove multi-point socket head bolt - 1 - for input shaft.

Scheme 535

1. Detach 6th speed selector gear with inner race for roller bearing and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10

Note. Check the gear teeth on the selector gears and gear wheels for damage after pulling them off.

1. Remove synchro-ring and needle bearing for 6th speed selector gear.

Scheme 536

1. Pull off 6th gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

1. Remove spacer sleeve from hollow shaft.

Scheme 537

1. Remove pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.

1. Mark installation position of locking collar in relation to synchronizing hub - arrow -.

1. Move selector fork - C - downward and detach with locking collar - D -.

Scheme 538

1. Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing hub for 5th and 6th gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

Note. Counter-hold two-arm puller using e.g. open end wrench - B -. If the needle bearing inner race for 6th gear is in contact with thrust pad con. 8/65 VW 433, insert lock pin 2064 into hole in input shaft to pull off the components all the way.

Scheme 539

1. Pull off 5th gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Note. The 5th gear wheel can also be pulled off together with the 4th gear wheel (Scheme 540).

Scheme 540

1. Pull off 4th gear wheel.

A - Puller, e.g. Kukko 18/2

Note. Counter-hold puller - A - using e.g. transmission holder 2004.

Scheme 541

1. Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

1. Counter-hold two-arm puller using e.g. open end wrench - B -.
2. Remove synchro-ring and needle bearing for 4th speed selector gear.

Scheme 542

1. Remove pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod - B -.

1. Mark installation position of locking collar in relation to synchronizing hub - arrow -.

1. Remove selector fork - C - with locking collar - D -.
2. Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.

Scheme 543

Remove 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.

A - Puller, e.g. Kukko 18/2

Note. Counter-hold puller - A - using e.g. transmission holder 2004 to prevent plate T40086 from making contact with 3rd gear wheel or selector rod for 5th and 6th gear.

1. Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.

Scheme 544

1. Pull off thrust washer - B - for 3rd speed selector gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Scheme 545

1. Remove bolts - arrows - for reverse shaft support.
2. Prevent pinion shaft from falling out and secure onto hollow shaft using e.g. a hose clip - A -.
3. Remove two bolts - B - securing bearing housing to transmission housing and detach bearing housing.
4. Remove hose clip from pinion shaft.

Scheme 546

1. Remove needle bearing - A - for pinion shaft - B - and pull out pinion shaft from hollow shaft - C -.

Scheme 547

1. Insert an internal puller - A - e.g. Kukko 21/2 into hole for reverse shaft support.
2. Spread open internal puller far enough for it to make contact with reverse shaft support - B -.
3. Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with reverse gear wheel.

Scheme 548

1. Remove circlip for 3rd gear wheel and note thickness of circlip.
2. Pull off 3rd gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Scheme 549

1. Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.

Scheme 550

1. Remove pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.

1. Mark installation position of locking collar in relation to synchronizing hub - arrow -.

1. Remove selector fork - C - with locking collar - D -.

Scheme 551

1. Press off synchronizing hub for reverse gear from hollow shaft.

Note. Place the bearing housing onto thrust plates VW 401 and VW 402 so that the hollow shaft and selector rods are not damaged when pressing off the synchronizing hub.

1. Remove reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
2. Guide hollow shaft out of selector fork for 1st and 2nd gear and bearing housing.