Input shaft needle bearing
2. Use a punch to drive the bearing out of the clutch housing. Install the new bearing so that the inscription on the bearing surface faces the drift used for installation. Insert the bearing into the hole on the side of the gearbox and, using a drift, drive it in, leveling it with the fill surface (photo).
Output shaft bearing
3. The outer ring of the bearing is secured with a pin that fits into a slot on the outer side of the bearing ring (photo). Grab the end of the pin and pull it out 3.2mm so that the other end releases the bearing ring. Using a punch, tap the outer race out of the housing. When installing a new outer ring, align the slot on the outside with the pin, insert the ring, align with the fill surface, insert the pin. Replacing the roller bearing assembly is a job for the Audi dealer; 3rd and 4th gears are firmly seated on the shaft and a special tool is required for removal. When installing the gears must be heated to 120°C.
Drive shaft flange seals
4. The drive shaft seals in the gearbox housing and final drive cover can be removed with a large screwdriver (photo).
5. Install the new seals with the insulation tabs facing in (photo).
6. After installing the oil seals, lubricate the projection with gear oil, fill the space between the projections with multipurpose grease.
Input shaft seal
7. Remove the clutch release bearing as described in Section 5.
8. Remove the three bolts holding the guide bush to the casing, remove the guide bush and plate (photo).
9. Remove the oil seal (photo). If it is necessary to remove the bushing, it can be pressed against the clutch housing using a piece of tubing of suitable diameter.
10. Insert the sleeve into the casing.
11. If the gland is mounted on the input shaft, put a piece of plastic insulating tube or tape around the grooves of the input shaft before sliding the gland onto the shaft. This will prevent damage to the seal by the grooves. Lubricate the oil seal lugs with gear oil. Drive the seal into place using a hammer and timber.
12. Install the guide bush and plate, tighten the bolts. If the guide bushing is plastic, it must be free of grease.
Starter bushing
13. The starter sleeve is located in the clutch housing, if worn, it must be replaced.
14. Insert a new starter bushing into the clutch housing.
Visitor comments