Table of contents: Disassembly and assembly of the… ↓ Gearbox lip seals ↓
Disassembly and assembly of the gearbox
1. Clutch module.
2. Clutch release lever with release bearing and retaining spring.
3. Bolt: 8 Nm; 2 pcs.; install with fixing agent -AMV 185 101 A1-.
4. Safety plate: not available in all configurations: installation position: countersink for bolts facing the clutch module. Absent since 02.2008. Absent when installing a new guide bushing.
5. Guide sleeve: remove (if available) grease from the guide bushing.
6. Ring for radial sealing of drive shaft.
7. Retaining ring: determine thickness; insert into the groove around the perimeter of the input shaft.
8. Carter KP.
9. Oil drain plug: 45 Nm.
10. Bolt: 200 Nm; for secondary shaft; install with fixing agent -AMV 185 101 A1-.
11. Cover: with oil guide; for secondary shaft; always subject to replacement.
12. Bolt: 10 Nm and 45° turn;aluminum bolts (M8; length 22 mm): 4 pcs.; always subject to replacement.
13. Shift shaft with cover: various versions are installed (with and without the "G701" gearbox neutral position sensor).
14. Sealing ring: always replaceable.
15. Bolt: 20 Nm, 30° turn; steel bolts (M8: length 30 mm): 3 pcs.; for support to the gearbox cover; install with locking compound "AMV 185 101 A1".
16. Gear shift sensor "F208": 20 Nm.
17. Half shaft with pinion of cylindrical gear transmission.
18. Bolt: 150 Nm 90° turn; for the axle shaft to the drive gear; always subject to replacement; 21mm bolt head (twelve-year student)
19. Bolt: 15 Nm 90° turn;steel bolts (M8; length 55 mm); 2 pcs.; always subject to replacement.
20. Double bolt: 15 Nm 90° turn; steel bolts (M8/M8; length 38 mm); 2 pcs.; not available on all designs, bolts are installed for this purpose; always subject to replacement
21. Bolt: 10 Nm 90° turn;aluminum bolts (M8; length 35 mm); 9 or 11 pcs.; always subject to replacement.
22. Locking cover.
23. Retaining ring: determine thickness; install into the circular groove of the secondary shaft.
24. Cylindrical gear: driving gear of the axle shaft (cylindrical gear transmission).
25. Gearbox cover.
26. Bolt: 15 Nm 90° turn;steel bolt (M8; length 50 mm); 1 pc.
27. Bolt: 10 Nm 90° turn;aluminum bolts (M8; length 35 mm); 16 pcs.; always subject to replacement.
28. Oil filler plug: 45 Nm.
29. Bolt: 10 Nm + tighten by 45°;aluminum bolts (M8; length 22 mm); for the neutral position sensor of the gearbox "G701" or plug and at the same time for the plug/shift shaft on the gearbox cover; not available in all trim levels; always subject to replacement.
30. Transmission neutral position sensor "G701" or plug: transmission neutral position sensor for vehicles with a start/stop system; not installed on gearboxes with the "G604" gear position sensor; the plug is installed in place of the G701 transmission neutral position sensor. If a plug is installed in place of the G701 transmission neutral position sensor, it does not need to be removed during disassembly and assembly of the transmission.
31. Sealing ring: always replaceable; installed on the gearbox with the "G701" gearbox neutral position sensor or a plug.
32. Mounting sleeve: 2 pcs.
33. Bolt: 15 Nm 45° turn;steel bolts (M8; length 25 mm); 3 pcs.
34. Left shaft with flange with shaft support.
Installation location of the gearbox neutral position sensor "G701" "1"
Only for vehicles with a start-stop system. Not installed on transmissions with the "G604" gear position sensor.
Installation location of the gear position sensor "G604"
1. Bolt, 10 Nm, and then tighten by 45° (replace).
2. Connector.
3. Gear recognition sensor.
4. Sealing rings.
Gearbox lip seals
The "C" and "D" lip seals can be replaced with the gearbox installed.
A. Primary shaft lip seal.
B. Left shaft lip seal with flange.
C. Right shaft lip seal with flange.
D. Gear selector shaft seal.
1. Right shaft with flange.
2. Main gear housing cover.
3. Sealing ring of the main gear housing cover.
4. Differential.
5. KP.
6. Left shaft with flange.
7. Clutch module.
8. Bolt: 10 pcs.
(Material republished from the website «AudiManual»)