Transmission, Assembling.: Notes

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 .

The reverse drive gear and the reverse shaft support must be installed 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.

Fig 1: Installing Input Shaft And Output Shaft Together With Shift Fork Group

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 2: Installing Reverse Drive Gear And Reverse Shaft Support

Courtesy of AUDI OF AMERICA, LLC

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

Fig 3: Attaching Support Tools T40214/1 And T40214/2 To Transmission Housing Using Bolt As Illustrated

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-- 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.

CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be installed together.
It is permissible to install the shaft alternating from side to side by turning each spindle maximum one turn.

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

-- 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-.

Fig 4: Removing Oil Catch Tray From Gearshift Rail / Shift Fork For 3Rd And 4Th Gears

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-- 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-.

Fig 5: Turning Transmission In Assembly Bracket So Transmission Cover Faces Up

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-- 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.