Controls, Housing (Manual Transmission Internal Components 0b2 Awd (coupe)) Audi A5 I

Scheme 202

1. Clutch Module Consists of the pressure plate, clutch disc and dual mass flywheel with transfer plate
2. Transmission Housing
3. Cover for Final Drive
4. Right Drive Flange
5. Differential With ring gear
6. Gear Set Pinion with ring gear / differential
7. Pinion
8. Reverse Gear
9. 1st Gear
10. 2nd Gear
11. Transmission Cover
12. Side Shaft With helical gear wheel
13. Center Differential Housing
14. Rear Flange Shaft
15. Center Differential
16. Spur Gear Side shaft drive wheel
17. 4th Gear
18. 3rd Gear
19. 6th Gear
20. 5th Gear
21. Input Shaft
22. Output Shaft
23. Flange Shaft, Left

Scheme 203

1. Left flange shaft, clutch module, side shaft, gearshift shaft and transmission cover, removing and installing, refer to «LEFT FLANGE SHAFT, CLUTCH MODULE, SIDE SHAFT, GEARSHIFT SHAFT AND TRANSMISSION COVER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) .
2. Center Differential Housing and Center Differential, Removing and Installing, refer to «CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__center-differential-housing-and-center-differential) .

CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW

Note. Removal can also be performed with the transmission still installed. Refer to REMOVAL AND INSTALLATION .

Scheme 204

1. Center Differential Housing With or without vibration dampener, depending on version Removing and installing, refer to «TRANSMISSION, ASSEMBLY SEQUENCE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__transmission-assembly-sequence) For servicing, refer to «CENTER DIFFERENTIAL HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__center-differential-housing)
2. Bolt Always replace 10 Nm plus an additional 90° turn Aluminum bolts (M8; 35 mm long) Qty. 9 or 11
3. Double Bolt Always replace 15 Nm plus an additional 90° turn Steel bolts (M8/M8; 38 mm long) Quantity: 2 Not installed on all versions
4. Bolt Always replace 15 Nm plus an additional 90° turn Steel bolts (M8; 55 mm long) Quantity: 2
5. Spring
6. Plate Spring Installed position: The camber on the inner diameter faces the center differential housing
7. Adjustment Shim
8. Center Differential Service by manufacturer only Center differential bearing, servicing, refer to «SPUR GEAR AND CENTER DIFFERENTIAL BEARING, SERVICING»(/audi/a5/i-2007-2011/remont/manual-trans/#gears-shafts-manual-transmission-internal-components-0b2-awd-coupe__spur-gear-and-center-differential-bearing)
9. Adjustment Shim For positioning the center differential Determining thickness, refer to «ADJUSTING SHIM S»(/audi/a5/i-2007-2011/remont/manual-trans/#gears-shafts-manual-transmission-internal-components-0b2-awd-coupe__adjusting-shim-s6-for-positioning-center)
10. Spacer Sleeve
11. End Shield Pay attention to the installed position to the transmission cover «INSTALL THE GEAR CARRIER ON THE TRANSMISSION COVER AS FOLLOWS»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
12. Spur Gear Side shaft/pinion drive wheel
13. Transmission Cover / Transmission

Scheme 205

1. Clutch Module Removing and installing, refer to «CLUTCH MODULE»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009__clutch-module) Servicing together with the clutch manufactured by Sachs, refer to «CLUTCH, SACHS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009__clutch-sachs-assembly-overview) Servicing together with the clutch manufactured by LuK, refer to «CLUTCH, LUK ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009__clutch-luk-assembly-overview)
2. Clutch Release Lever with Release Bearing and Spring Removing and installing, refer to «CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009) Disassembling and assembling, refer to «CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009)
3. Bolt 8 Nm Quantity: 2 Insert with locking fluid AMV 185 101 A1
4. Securing Plate Not installed on all versions Installed position: the recess for the bolts -3- faces the clutch module NOTE: Deleted from 02.2008 Also deleted when installing a new guide sleeve refer to item -8- under «CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009)
5. Guide Sleeve If present, remove any grease from the guide sleeve
6. Input Shaft Seal Removing and installing, refer to «INPUT SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__input-shaft-seal)
7. Securing Ring Determining thickness «DETERMINE THE LOCKING RING -ARROW- FOR THE INPUT SHAFT AS FOLLOWS»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__determine-the-locking-ring-arrow-for) Insert in input shaft surrounding groove
8. Transmission Housing Input and Output shafts with shift Rails and Shift Forks, Removing and Installing, refer to «INPUT SHAFT, OUTPUT SHAFT, REVERSE DRIVE GEAR AND SHIFT RAILS/SHIFT FORKS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) For servicing, refer to «TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__transmission-housing) Differential, Removing and Installing, refer to «DIFFERENTIAL ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__differential-assembly-overview)
9. Oil Drain Plug 45 Nm
10. Bolt 200 Nm For output shaft Insert with locking fluid AMV 185 101 A1
11. Sealing Cap Always replace With oil guide For output shaft
12. Bolt Always replace 10 Nm plus an additional 45° turn Aluminum bolts (M8; 22 mm long) Quantity: 4
13. Selector Shaft with Selector Cover Different versions are installed (with and without a transmission neutral position sensor -G701-)
14. O-Ring Always replace
15. Bolt 20 Nm plus an additional 30° turn Steel bolts (M8; 30 mm long) Quantity: 3 For the bearing bracket to the transmission cover Insert with locking fluid AMV 185 101 A1
16. Transmission Range Gear Recognition Switch -F208- 20 Nm
17. Side Shaft With helical gear wheel
18. Bolt Always replace 150 Nm + 90° additional turn For the side shaft to the pinion Bolt head, 21 mm (12-point)
19. End Shield Pay attention to the installed position to the transmission cover, refer to «TRANSMISSION, ASSEMBLY SEQUENCE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__transmission-assembly-sequence)
20. Spur Gear Side shaft/pinion drive wheel
21. Needle Bearing For the spur gear -20- Mount on the output shaft
22. Transmission Cover For servicing, refer to «TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__transmission-cover)
23. Bolt 15 Nm plus an addition 90° turn Steel bolt (M8; 50 mm long) Quantity: 1
24. Bolt Always replace 10 Nm plus an additional 90° turn Aluminum bolts (M8; 35 mm long) Quantity: 16
25. Oil Fill Plug 45 Nm
26. Bolt Always replace 10 Nm plus additional 45° turn Aluminum bolt (M8; 22 mm long) For the transmission neutral position sensor -G701- or the plug and at the same time for the cover/gearshift shaft to the transmission cover Not installed on all versions
27. Transmission Neutral Position Sensor -G701- or Cap Transmission neutral position sensor for vehicles with the Start/Stop System A cap is installed in place of the transmission neutral position sensor -G701- NOTE: It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor -G701-.
28. O-Ring Always replace On transmissions with a transmission neutral position sensor -G701- or a cap
29. Alignment Bushing Quantity: 2
30. Bolt 15 Nm plus an additional 45° turn Steel bolts (M8; 25 mm long) Quantity: 3
31. Flange Shaft, Left With bracket

Scheme 206

1. Transmission Housing With differential and pinion
2. Oil Collector Tray Clipped into the bearing bracket and the gearshift rail/shift fork for 3rd and 4th gears
3. Input and Output Shafts with Shift Fork Group Disassembling and assembling, refer to «SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/manual-trans/#gears-shafts-manual-transmission-internal-components-0b2-awd-coupe)
4. Reverse Drive Gear With support/reverse shaft Reverse drive gear assembly overview «REVERSE DRIVE GEAR ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
5. Magnet Clean

Scheme 207

1. Thrust washer
2. Needle bearing
3. Reverse drive gear NOTE: Installed position: The shoulder -arrow- faces the transmission housing.
4. Reverse shaft support

FASTENER TIGHTENING SPECIFICATIONS

TRANSMISSION, ASSEMBLY SEQUENCE

Center Differential Housing, Center Differential, Side Shaft, Transmission Cover, Input and Output Shafts Together with Transmission-Side Shift Mechanism, Removing and Installing

Note. You do not need to remove the differential when removing the components listed above. Refer to general repair instructions. Refer to GENERAL REPAIR INFORMATION .

Special tools and workshop equipment required

1. Driving Sleeve VW 244 B
2. Thrust Piece 40 -105
3. Socket, Multi Point Bit XZN 14 T10061
4. Pulling Hook T20143
5. Thrust Piece T40166
6. Extractor T40176
7. Driver 3013
8. Gearbox Support T40206
9. Assembly Tool T40213
10. Support Tool T40214
11. Guide Pin T40216
12. Counterhold Tool T40217
13. Clamping Sleeve 3116
14. Counterhold Tool T40215
15. Thread Locking Compound AMV 185 101 A1
16. Sealing Paste AMV 188 001 02
17. Grease for Clutch Disc Shaft Splines G 000 100
18. Adhesive Lubricating Paste G 000 150
19. Sealing Grease G 052 128 A1

TRANSMISSION, DISASSEMBLING

Place drip tray underneath.

Remove the bolt -arrow- and drain the transmission oil.

Scheme 208

Secure the transmission holder T40206 to the transmission with the bolts -arrows- and tighten it in the assembly stand.

Scheme 209

Remove the clutch module. Refer to CLUTCH MODULE .

Set the clutch module down carefully, for example on the workbench.

Remove the clutch release lever -1- together with the release bearing -2- and the spring -3-.

Scheme 210

Remove the bolts -4-, the locking plate -5- (if equipped) and the guide sleeve -6-.

Pry out the input shaft seal.

Scheme 211

Circlip -arrow- in front of the ball bearing of input shaft must then be removed.

Scheme 212

Note. If it is not possible to remove the locking ring, then remove the transmission cover first and then move the input shaft forward using a rubber hammer.

Push the cover -A- for the output shaft in the center and pry it out in direction of -arrow-.

Scheme 213

Remove the bolts -A-, -B- and -arrows- that attach the center differential housing -C- to the transmission cover.

Scheme 214

Note. Not all versions have the double bolts -B- ; allocation.

Carefully remove the center differential housing -6-, the pressure spring -3-, the adjusting shim -4- and the plate spring -5-.

Scheme 215

Remove the center differential -2- and the gear carrier -1-.

If the gear carrier -1- remains in the center differential housing, proceed as follows

Scheme 216

Grip the side ridge on the gear carrier -1- using a pair of pliers and remove it in direction of -arrow A-.

Using a rubber hammer, tap the housing on alternating sides -B arrows-.

Loosen the twelve-point bolt -A- for the side shaft -B- on the pinion as follows

Scheme 217

Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

Insert the T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

Secure the T40217 to the transmission cover with the M8 bolt -arrows-.

Scheme 218

Remove the side shaft twelve-point bolt on the pinion.

A - torque wrench

Mount the T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Scheme 219

Note. The T40217 remains attached to the transmission cover. The output shaft will be blocked after the special tool is installed and will not turn.

Loosen the bolt -A- on the output shaft using the T10061.

Scheme 220

Note. The bolt -A- has a very high loosening torque (approximately 300 to 350 Nm).

B - Torque Wrench

Remove the T40215 and T40217.

Remove the side shaft -1- from the transmission cover.

Scheme 221

Remove the spur gear -2- for the spur gear and the needle bearing from the output shaft -3-.

If equipped, remove the transmission neutral position sensor -G701- -A-.

Scheme 222

Remove the bolt -arrow- and remove the sensor from the cover -B-.

Note. The cover -B- remains installed. It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor.

Remove the bolts -1- and pry the selector shaft cover -2- off carefully.

Scheme 223

Raise the selector shaft slightly -arrow A- and remove it -arrow B-.

Scheme 224

Then turn transmission in assembly bracket so transmission cover -C- faces up.

Scheme 225

Remove the bolts -A- (for the bearing bracket) and the bolts -B- that attach the transmission cover -C- to the transmission housing -D-.

Note. Make sure the bolt -arrow- is a 50 mm steel bolt when installing the transmission cover.

Remove the transmission cover -C-.

Remove the oil catch tray -1- from the gearshift rail / shift fork for 3rd and 4th gears -2- and from the bearing bracket -3- -arrows A through D-.

Scheme 226

Attach the T40213 to the T40206 using the bolts -arrows-.

Scheme 227

Remove the input and output shafts from the ball bearings inside the transmission housing by turning the spindles on the T40213 one turn and alternating from side to side.

At the same time, remove the reverse shaft support -2- from the transmission housing -arrow B-.

Scheme 228

Remove the reverse drive gear -1- and the reverse shaft support -2- from the drive axle.

Remove the input shaft -1- and the output shaft -2- together with the shift fork group -3- from the transmission housing.

Scheme 229

Remove the oil catch tray -4- and the magnet -5-.

TRANSMISSION, ASSEMBLING.

Note. The adjusting shim for the bearing tension on the spur gear tapered roller bearing must be determined again whenever replacing the transmission cover, the spur gear, the spur gear tapered roller bearing, the gear carrier or the center differential housing. Refer to SPUR GEAR TAPERED ROLLER BEARING PRE-LOAD, DETERMINING .

1. The reverse drive gear and the reverse shaft support must be installed «TRANSMISSION, ASSEMBLY SEQUENCE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__transmission-assembly-sequence) before the input and output shafts touch the bearing seat in the ball bearing.

Install the oil catch tray -4- and the magnet -5- into the transmission housing.

Install the input shaft -1- and the output shaft -2- together with the shift fork group -3- into the transmission housing.

Install the reverse drive gear -1- and the reverse shaft support -2-. When doing this, insert the tab -arrow A- into the opening -arrow B- in the transmission housing.

Attach the support tools T40214/1 and T40214/2 to the transmission housing using the bolt -1- and -2-, as illustrated.

Scheme 230

Attach the plate T40213/1 to the support tools T40214/1 and T40214/2.

Mount the 3116 and on the output shaft and the 40-105 on the input shaft.

Then install the input and output shafts all the way into the ball bearing by turning the spindles T40213/2 one turn alternating from side to side.

Remove the T40213 and the T40214.

Install the oil catch tray -1- with the tab -arrow A- into the hole -arrow B- in the bearing bracket -3- and then install the bearing bracket -arrow C- and the gearshift rail / shift fork for 3rd and 4th gears -2- -arrow D-.

Make sure the 2 alignment bushings for centering the transmission cover / transmission housing are inside the transmission housing.

Apply sealing paste AMV 188 001 02 evenly and not to thick on transmission housing joint surfaces at transmission cover.

Mount the transmission cover -C- on the transmission housing -D-.

Clean bolt threads -A- with a wire brush. Install the bolts with locking fluid AMV 185 101 A1 and install them hand-tight into the bearing bracket.

Tighten the new aluminum bolts (quantity: 16; 35 mm long) -B- to the tightening specification.

Tighten the steel bolt -arrow- (50 mm long) under the hole for the clutch slave cylinder to the tightening specification.

Then tighten the bolts -A- to the tightening specification.

DETERMINE THE LOCKING RING -ARROW- FOR THE INPUT SHAFT AS FOLLOWS

Determine thickest circlip which can still just be installed and insert it. For the part number.

Note. Begin wit the thickest locking ring.

The following locking rings are available

Mount the spur gear -2- and the needle bearing -21- LEFT FLANGE SHAFT, CLUTCH MODULE, SIDE SHAFT, GEARSHIFT SHAFT AND TRANSMISSION COVER ASSEMBLY OVERVIEW on the output shaft -3-.

Note. The adjusting shim for positioning the center differential must be determined again when the transmission cover, the spur gear, the spur gear tapered roller bearing or the spacer sleeve are replaced. Refer to ADJUSTING SHIM S .

Install the side shaft -1- all the way into the transmission cover.

Tighten the twelve-point bolt -A- for the side shaft -B- on the pinion as follows

Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

Insert the T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

Secure the T40217 to the transmission cover with the M8 bolt -arrows-.

Tighten the side shaft twelve-point bolt to the pinion to the tightening specification.

A- torque wrench

Mount the T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Note. The T40217 remains attached to the transmission cover. The output shaft will be blocked after the special tool is attached and will not turn.

Clean the threads on the bolt -A- on the output shaft with a wire brush. Then install and tighten the bolts with locking fluid AMV 185 101 A1 to the tightening specification.

B - Torque Wrench

Remove the T40215 and T40217.

Lightly coat the cover -A- for the output shaft with oil on the outer circumference and then install it.

Scheme 231

Lightly oil outer circumference of new shaft seal for the input shaft.

Scheme 232

Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

Drive the new seal in until it is flush without tilting it.

Scheme 233

1. Installed position: the tab -arrow A- on the gear carrier -2- must installed into the opening -arrow B- inside the transmission cover.

Install the oil catch tray -1-.

Mount the spacer sleeve -3- and the adjusting shim -4- (for positioning the center differential) on the output shaft.

Slide the center differential -2- all the way in direction of the gear carrier -1-.

Insert the plate spring -5-, the adjustment shim(s) -4- and the spring -3- in the center differential housing -6-.

1. Plate spring installed position -5- : the inner diameter with it camber -arrow- faces the center differential housing -6-.

Apply sealing paste AMV 188 001 02 evenly and not too thick.

Then position the center differential housing -6- on the transmission.

Press the center differential housing -C- on until it makes contact with the transmission cover and hold it securely.

Install the new bolts -A-, -B- and -arrows- and tighten them to the tightening specification.

Note. Not all versions have the double bolts -B- ; allocation, Bolts are installed in place of the double bolts -2- CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW .

Install the new O-ring on the cover -2-.

Scheme 234

Install the T40216 on the selector shaft -1-.

Insert the selector shaft in the transmission -arrow A- by raising it slightly -arrow B-.

Scheme 235

Bring the selector shaft cover -2- into contact with the transmission housing.

Tighten the new bolts -1- to the tightening specification.

Remove T40216.

If equipped, install the transmission neutral position sensor -G701- -A- with a new O-ring in the gearshift shaft cover -B-.

Tighten new bolt -1- to the tightening specification.

Install the guide sleeve -6- and the locking plate -5-, if equipped.

Clean bolt threads -4- with a wire brush. Then install and tighten the bolts with locking fluidAMV 185 101 A1 to the tightening specification -6- CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW => Bolt .

Install the clutch release lever -1- together with the release bearing -2- and the spring -3-. Refer to CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW .

Scheme 236

Install the clutch module and the left flange shaft INSTALL THE CLUTCH MODULE .

Fill the transmission with transmission fluid and check the level. Refer to GENERAL INFORMATION . Remove the oil filler plug -arrow-.

Scheme 237

CENTER DIFFERENTIAL HOUSING

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Tube 60 mm Dia. VW 415 A
5. Press Tube 30 - 100
6. Press Tube 2040
7. Thrust Piece T40165
8. Thread Locking Compound AMV 185 101 A1
9. Sealing Grease G 052 128 A1

Scheme 238

1. Center Differential Service by manufacturer only
2. Spring
3. Adjustment Shim
4. Plate Spring Installed position: the camber on the inner diameter faces toward the flange shaft
5. Spacer Sleeve Removing «INSTALLING THE FLANGE SHAFT BALL BEARING AND SPACER SLEEVE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «REMOVING THE FLANGE SHAFT BALL BEARING AND SPACER SLEEVE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
6. Securing Ring For flange shaft Removing and installing, refer to «REMOVE THE CIRCLIP -ARROW-.»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
7. Ball Bearing For flange shaft Removing «INSTALLING THE FLANGE SHAFT BALL BEARING AND SPACER SLEEVE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «REMOVING THE FLANGE SHAFT BALL BEARING AND SPACER SLEEVE»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
8. Shaft Seal Prying out «PRYING OUT THE SHAFT SEAL -1»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__prying-out-the-shaft-seal-1) Installing «INSTALLING THE SEAL FOR THE REAR FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
9. Rear Flange Shaft Without vibration damper Allocate components shims. Removing «PRESSING OUT FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__pressing-out-flange-shaft) Installing «PRESSING IN FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
10. Rear Flange Shaft With vibration damper Allocate components shims. Removing «PRESSING OUT FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__pressing-out-flange-shaft) Installing «PRESSING IN FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
11. Bolt 15 Nm plus an additional 90° turn For vibration damper Quantity: 3 Insert with locking fluid AMV 185 101 A1
12. Vibration Damper Not present on all versions Allocate according to transmission code.
13. Center Differential Housing Removing and installing with transmission installed, refer to «REMOVAL AND INSTALLATION»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe)

Scheme 239

Scheme 240

1. The shoulder on the VW 415 A -arrow- faces toward the VW 412.

Scheme 241

PRYING OUT THE SHAFT SEAL -1

Note. Ignore -2-.

Scheme 242

Lightly coat the shaft seal on the outer circumference with oil and then install it.

Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

PRESSING OUT FLANGE SHAFT

Remove the circlip before remove the flange shaft REMOVE THE CIRCLIP -ARROW-. .

Position the center differential housing so the flange shaft does not come into contact with the VW 401 and VW 402 when pressing it off.

Scheme 243

Scheme 244

Tighten the vibration damper, if applicable, before pressing the flange shaft in. Tightening specification -11- CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW .

TRANSMISSION COVER

Special tools and workshop equipment required

1. Arbor VW 204 B
2. Drift VW 207 C
3. Punch VW 408 A
4. Punch VW 411
5. Punch VW 412
6. Sleeve VW 420
7. Sleeve VW 423
8. Arbor VW 434
9. Sleeve VW 472/2
10. Thrust Pad VW 512
11. Guide Pin 10 - 15
12. Sleeve 40 - 21
13. Thrust Pad 3005
14. Drift 3138
15. Extension 3161
16. Support Arm Bearing Inst. Tool 3346
17. Guide Bearing Inst. Tool 3347
18. Shock Absorber Set T10001
19. Pulling Hook T20143
20. Drift T40085
21. Pressure Sleeve T40103
22. Sealing Paste AMV 188 001 02
23. Sealing Grease G 052 128 A1

Scheme 245

1. Large Securing Bushing For selector shaft Removing and installing «REMOVING AND INSTALLING THE LARGE LOCKING BUSHING -1- ON THE GEARSHIFT SHAFT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__removing-and-installing-the-large-locking) Installation dimension «INSTALLED DIMENSION FOR THE LARGE LOCKING BUSHING -1- INSIDE THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__installed-dimension-for-the-large-locking)
2. Securing Bushing For the gearshift rail / shift fork Removing and installing, refer to is currently not possible.
3. Needle Bearing Always replace For the side shaft bearing Remove from the transmission cover using the 3138 Driving in «INSTALLING THE NEEDLE BEARING ALL THE WAY INTO THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__installing-the-needle-bearing-all-the) Secure after installing with peen «SECURING THE NEEDLE BEARING INSIDE THE TRANSMISSION COVER BY PEENING IT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__securing-the-needle-bearing-inside-the)
4. Oil Collector Tray Install in the openings in the transmission cover and roller sleeves -6
5. Outer Race / Tapered Roller Bearing For the gear wheel mounting inside the transmission cover Removing «PRESSING TAPERED ROLLER BEARING OUTER RACE OUT FROM THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «INSTALLING THE OUTER RACE / TAPERED ROLLER BEARING ALL WAY INTO THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
6. Roller Sleeve For the input shaft mounting Removing «REMOVING THE INPUT SHAFT ROLLER SLEEVE FROM THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «INSTALLING THE INPUT SHAFT ROLLER SLEEVE -A- ALL THE WAY INTO THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
7. Transmission Cover
8. O-Ring Always replace Installed only on transmissions with a cover / gearshift shaft together with a transmission neutral position sensor -G701- or cap
9. Sealing Cap For the gearshift shaft together with a transmission neutral position sensor or a cap Not present on all versions Allocate according to transmission code. Assembly overview «ASSEMBLY OVERVIEW - GEARSHIFT SHAFT COVER WITH A HOLE -ARROW- FOR THE TRANSMISSION NEUTRAL POSITION SENSOR -G701- OR CAP»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Selector shaft seal, removing and installing «GEARSHIFT SHAFT COVER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Remove the gearshift shaft ball sleeve «REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Install the gearshift shaft ball sleeve «INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- UP TO DIMENSION -X- INTO THE COVER -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
10. Sealing Cap Not present on all versions Allocate according to transmission code. Replace the O-ring with a cap, use the transmission code to allocate.
11. Bolt Always replace 10 Nm plus an additional 45° turn Aluminum bolts (M8; 22 mm long)
12. Transmission Neutral Position Sensor -G701- Not present on all versions Allocate according to transmission code. Replace the O-ring on the transmission neutral position sensor, allocate according to the transmission code.
13. Sealing Cap For the gearshift shaft without a transmission neutral position sensor or a cap Not present on all versions Allocate according to transmission code. Removing and installing, refer to «REMOVING AND INSTALLING THE GEARSHIFT SHAFT COVER -A»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Assembly overview «GEARSHIFT SHAFT COVER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Selector shaft seal, removing and installing «GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__gearshift-shaft-seal-removing-and-installing) Remove the gearshift shaft ball sleeve «REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Install the gearshift shaft ball sleeve «INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- EVENLY IN THE COVER -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
14. Bushing For the 3rd/4th gear gearshift rail / shift fork Removing «REMOVING THE BEARING BUSHING FOR THE 3RD AND 4TH GEAR GEARSHIFT RAIL /. FROM THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «INSTALLING THE BEARING BUSHING -A- FOR THE 3RD AND 4TH GEAR GEARSHIFT RAIL / SHIFT FORK ALL THE WAY INTO THE TRANSMISSION COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
15. Small Locking Bushing For selector shaft Removing and installing is currently not possible.

REMOVING AND INSTALLING THE LARGE LOCKING BUSHING -1- ON THE GEARSHIFT SHAFT

1. The gearshift shaft must be removed.
2. If the transmission is not disassembled, place a cloth in the opening for the gearshift shaft to prevent the locking bushing from falling into the transmission.

Remove the large locking bushing using the T40085 toward the inside, in the transmission cover.

Scheme 246

Install the locking bushing using the T40085 to the installation dimension INSTALLED DIMENSION FOR THE LARGE LOCKING BUSHING -1- INSIDE THE TRANSMISSION COVER .

INSTALLED DIMENSION FOR THE LARGE LOCKING BUSHING -1- INSIDE THE TRANSMISSION COVER

Check the installed dimension -a- = 5 ± 0.2 mm with a depth gauge -2-.

Scheme 247

1. Insert the depth gauge on the first shoulder -arrow- of the locking bushing.

INSTALLING THE NEEDLE BEARING ALL THE WAY INTO THE TRANSMISSION COVER

Note. Remove peening indentations, if present.

Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards VW 204 B.

Scheme 248

Secure needle bearing after pressing into transmission cover with peen SECURING THE NEEDLE BEARING INSIDE THE TRANSMISSION COVER BY PEENING IT .

SECURING THE NEEDLE BEARING INSIDE THE TRANSMISSION COVER BY PEENING IT

To peen, use blunt center punch with ball-shaped end (ball diameter 5 mm).

Needle bearing is secured with 4 peening marks on circumference every 90° -arrows-.

Scheme 249

Observe position and diameter of peening points

1. Dimension -a- = 2 mm
2. Dimension -b- = 3 mm

Scheme 250

Scheme 251

Scheme 252

Scheme 253

1. Mount the roller sleeve with the shoulder into the open side of the 3346.

Scheme 254

1. The gearshift shaft is removed.

Remove the bolts that attach the cover -A- to the transmission cover.

Remove the cover using the VW 420 in direction of -arrow-.

Clean the sealing surfaces on the cover and transmission cover.

Apply sealing compound AMV 188 001 02 evenly and use new bolts to attach the cover -11- TRANSMISSION COVER .

Scheme 255

1. Selector shaft seal, removing and installing GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING
2. Sealing cap
3. Gearshift shaft ball sleeve, removing «REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) and installing «INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- EVENLY IN THE COVER -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)

Scheme 256

1. Selector shaft seal, removing and installing «GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__gearshift-shaft-seal-removing-and-installing)
2. Sealing cap
3. Gearshift shaft ball sleeve, removing «REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) and installing «INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- UP TO DIMENSION -X- INTO THE COVER -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
4. O-Ring

GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING

Pry out the shaft seal using the T20143/1.

Lightly oil outer circumference of shaft seal.

Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

Install the shaft seal using the T10001/1 or the tube VW 423.

Scheme 257

1. Installed dimension: 2 mm under the upper edge of the cover

Scheme 258

Scheme 259

Set ball sleeve in place with inscribed side (thicker wall) facing toward 10 - 15.

Scheme 260

Set ball sleeve in place with inscribed side (thicker wall) facing toward 10 - 15.

1. Installed dimension -x- = 2.5 ± 0.5 mm

Scheme 261

Scheme 262

Install the 3161 and shoulder -arrow 1- in the bearing bushing -A-.

Install the bearing bushing all the way using the VW 207 C and at the same time with the shoulder -arrow 2- into the 3161.

TRANSMISSION HOUSING

Special tools and workshop equipment required

1. Driving Sleeve VW 244 B
2. Slide Hammer-Complete Set VW 771
3. Locking Pin 30 - 505
4. Sleeve 40 - 20
5. 1- Internal Puller Kukko 21/3
6. Adhesive Lubricating Paste G 000 150

Note. It is not possible to disassemble and assemble the differential. Removing and installing the pinion is currently not possible. Adjusting the pinion and the ring gear is currently not possible. Replacement: replace the differential housing together with the installed pinion and differential.

Scheme 263

1. Intermediate Piece Replace if damaged
2. Ball Studs 25 Nm Lubricate the bearing surface for the clutch release lever with adhesive lubricating paste G 000 150
3. Cap For transmission breather
4. Breather Pipe Installation dimension «BREATHER PIPE INSTALLATION DIMENSION»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe__breather-pipe-installation-dimension) Unclip transmission breather cap
5. Shaft Seal For left flange shaft Removing and installing, refer to «LEFT FLANGE SHAFT SEAL WITH TRANSMISSION REMOVED»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__left-flange-shaft-seal-with-transmission)
6. Differential Can currently be replaced only with the transmission housing and the pinion NOTE: The differential bevel gears cannot be removed or installed.
7. O-Ring Always replace Coat with transmission fluid
8. Cover for Final Drive Replace, refer to «FINAL DRIVE COVER»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__final-drive-cover)
9. Bolt 20 Nm plus an additional 90° turn Steel bolts (M8; 38 mm long) Quantity: 10
10. Right Drive Flange With circlip Removing and installing, refer to «RIGHT FLANGE SHAFT SEAL WITH TRANSMISSION REMOVED»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__right-flange-shaft-seal-with-transmission)
11. Shaft Seal For right flange shaft Removing and installing, refer to «RIGHT FLANGE SHAFT SEAL WITH TRANSMISSION REMOVED»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-manual-transmission-internal-components-0b2-awd-coupe__right-flange-shaft-seal-with-transmission)
12. Oil Collector Tray
13. Pinion Can currently be replaced only with the transmission housing and the differential
14. Bushing For the gearshift rail / shift fork Quantity: 3 Removing «INSTALLING THE OUTPUT SHAFT BALL BEARING -A- IN THE TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Installing «INSTALLING THE BEARING BUSHING -ARROW- FOR THE GEARSHIFT RAIL / SHIFT FORK»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
15. Ball Bearing For output shaft Driving out «INSTALLING THE OUTPUT SHAFT BALL BEARING -A- IN THE TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Driving in «INSTALLING THE OUTPUT SHAFT BALL BEARING -A- IN THE TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
16. Securing Ring Installation location «INSTALLED POSITION: LOCKING RINGS -A- FOR THE BALL BEARINGS -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
17. Securing Ring Installation location «INSTALLED POSITION: LOCKING RINGS -A- FOR THE BALL BEARINGS -B»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
18. Ball Bearing For input shaft Driving out «INSTALLING THE INPUT SHAFT BALL BEARING -A- IN THE TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe) Driving in «INSTALLING THE INPUT SHAFT BALL BEARING -A- IN THE TRANSMISSION HOUSING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-internal-components-0b2-awd-coupe)
19. Magnet Clean
20. Oil Drain Plug 45 Nm
21. Transmission Housing Can currently be replaced only with the differential and the pinion

BREATHER PIPE INSTALLATION DIMENSION

Dimension -a- = 21.5 mm

Scheme 264

Scheme 265

A

Internal puller 18.5 to 23.5 mm, for example Kukko 21/3

Scheme 266

Scheme 267

1. Remove the ball bearing locking ring before hand.

Scheme 268

Install the ball bearing locking ring paying close attention to the installed position of the locking ring INSTALLED POSITION: LOCKING RINGS -A- FOR THE BALL BEARINGS -B .

Scheme 269

1. Remove the ball bearing locking ring beforehand.

Scheme 270

Install the ball bearing locking ring paying close attention to the installed position of the locking ring INSTALLED POSITION: LOCKING RINGS -A- FOR THE BALL BEARINGS -B .

Scheme 271

1. The bevel -arrow- on the locking ring -A- faces away from the ball bearing -B-.

Note. The locking rings and the ball bearings for the input and output shafts are identical.

GEARSHIFT RAILS AND SELECTOR FORKS

Note. Gearshift rails / shift forks installed positions inside the transmission GEARSHIFT RAILS / SHIFT FORKS INSTALLED POSITIONS INSIDE THE TRANSMISSION. . Removing the shift fork group from the bearing brackets for the input and output shafts. Refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .

Scheme 272

1. Gearshift Rail / Reverse Gear Shift Fork
2. Gearshift Rail / Shift Fork for 1st and 2nd Gear
3. Ball Sleeve Remove and install, for example, using locking ring pliers (for the outer races) from the gearshift rail / shift fork
4. Gearshift Rail / Shift Fork for 3rd and 4th Gear
5. Gearshift Rail / Shift Fork for 5th and 6th Gear With yoke for the gearshift rail / shift fork mounting The shift fork cannot be separated from the yoke.

Scheme 273

1. Gearshift rail / reverse gear shift fork
2. Gearshift rail / shift fork for 1st and 2nd gear
3. Gearshift rail / shift fork for 3rd and 4th gear
4. Gearshift rail / shift fork for 5th and 6th gear

Scheme 274

Special tools and workshop equipment required

1. Driving Sleeve VW 244 B
2. Thrust Piece 40 -105
3. Socket, Multi Point Bit XZN 14 T10061
4. Pulling Hook T20143
5. Thrust Piece T40166
6. Extractor T40176

Scheme 275

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Tube 60 mm Dia. VW 415 A
5. Press Tube 30 - 100
6. Press Tube 2040

Scheme 276

Special tools and workshop equipment required

1. Arbor VW 204 B
2. Drift VW 207 C
3. Punch VW 408 A
4. Punch VW 411
5. Punch VW 412
6. Sleeve VW 420

Scheme 277

Special tools and workshop equipment required

1. Sleeve VW 423
2. Arbor VW 434
3. Sleeve VW 472/2
4. Thrust Pad VW 512
5. Guide Pin 10 - 15
6. Sleeve 40 - 21

Scheme 278

Special tools and workshop equipment required

1. Thrust Pad 3005
2. Drift 3138
3. Extension 3161
4. Support Arm Bearing Inst. Tool 3346
5. Guide Bearing Inst. Tool 3347
6. Shock Absorber Set T10001

Scheme 279

Special tools and workshop equipment required

1. Driving Sleeve VW 244 B
2. Slide Hammer-Complete Set VW 771
3. Locking Pin 30 - 505
4. Sleeve 40 - 20
5. 1- Internal Puller Kukko 21/3

Scheme 280

Special tools and workshop equipment required

1. Driver 3013
2. Gearbox Support T40206
3. Assembly Tool T40213
4. Support Tool T40214
5. Guide Pin T40216
6. Counterhold Tool T40217

Special tools and workshop equipment required

Scheme 281

Scheme 282

Scheme 283

Scheme 284

1. Clamping Sleeve 3116
2. Thrust Piece T40165
3. Drift T40085
4. Pressure Sleeve T40103
5. Counterhold Tool T40215

See also:
• REMOVAL AND INSTALLATION
• SPUR GEAR AND CENTER DIFFERENTIAL BEARING, SERVICING
• ADJUSTING SHIM S
• CLUTCH MODULE
• CLUTCH, SACHS ASSEMBLY OVERVIEW
• CLUTCH, LUK ASSEMBLY OVERVIEW
• CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE
• INPUT SHAFT SEAL
• DIFFERENTIAL ASSEMBLY OVERVIEW
• SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW
• GENERAL REPAIR INFORMATION
• SPUR GEAR TAPERED ROLLER BEARING PRE-LOAD, DETERMINING
• DUAL MASS FLYWHEEL NEEDLE BEARING, SACHS AND LUK
• INSTALL THE CLUTCH MODULE
• LEFT FLANGE SHAFT SEAL WITH TRANSMISSION REMOVED
• FINAL DRIVE COVER
• RIGHT FLANGE SHAFT SEAL WITH TRANSMISSION REMOVED
• LEFT FLANGE SHAFT, CLUTCH MODULE, SIDE SHAFT, GEARSHIFT SHAFT AND TRANSMISSION COVER ASSEMBLY OVERVIEW
• CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW
• TRANSMISSION, ASSEMBLY SEQUENCE
• CENTER DIFFERENTIAL HOUSING
• DETERMINE THE LOCKING RING -ARROW- FOR THE INPUT SHAFT AS FOLLOWS
• TRANSMISSION HOUSING
• TRANSMISSION COVER
• PRYING OUT THE SHAFT SEAL -1
• PRESSING OUT FLANGE SHAFT
• REMOVING AND INSTALLING THE LARGE LOCKING BUSHING -1- ON THE GEARSHIFT SHAFT
• INSTALLED DIMENSION FOR THE LARGE LOCKING BUSHING -1- INSIDE THE TRANSMISSION COVER
• INSTALLING THE NEEDLE BEARING ALL THE WAY INTO THE TRANSMISSION COVER
• SECURING THE NEEDLE BEARING INSIDE THE TRANSMISSION COVER BY PEENING IT
• GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING
• BREATHER PIPE INSTALLATION DIMENSION