4WD AUDI A6 2000 C5 / 2.G Changing Clutch 5Speed Manual Gearbox

Dismantling and assembling gearbox Removing and installing input shaft ball bearing, multi-function sender, input
shaft, drive pinion, selector rods, gearbox cover and cover with Torsen differential Special tools and workshop
equipment required
â—† VW 309
Holding plate
â—† VW 353
Gearbox
support
â—† 3235
Pressing-in
tool
â—† 3357 Socket
attachment
â—† V.A.G 1582
Taper roller
bearing puller
â—† V.A.G 1582/2
Grip piece Special tools and workshop equipment required
â—† V.A.G 1306 Drip tray Page 1 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

â—† V.A.G 1331 Torque wrench
â—† Sealant AMV 188 001 02 Notes:
â—† It is not necessary to remove the
differential to remove the above-
mentioned components => Page 34-74.
â—† Removal is only necessary when
adjustments have to be carried out
=> adjustment overview, Page 39-45.
Removing
‒ Place drip tray V.A.G 1306
underneath the gearbox.
‒ Drain gearbox oil using socket
attachment 3357.
‒ → Secure gearbox in assembly
stand VW 540. Page 2 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Detach clutch release lever -A-
with release bearing.
Notes:
â—† Before pulling off guide sleeve, cover input shaft splines with a shrink-fit
hose to protect oil seal.
â—† Removing oil seal from guide sleeve
=> Page 30-32.
‒ Unscrew guide sleeve -B-.
‒ Remove dished washer -C-.
‒ Remove circlip -D- in front of input
shaft ball bearing. ‒ If the ball bearing, input shaft or
gearbox housing is not to be
replaced, note the thickness of the
circlip.
‒ → Pull the input shaft ball bearing
out of the gearbox housing. Page 3 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Remove the circlip (arrow) behind
the input shaft ball bearing.
‒ If the ball bearing, input shaft or
gearbox housing is not to be
replaced, note the thickness of the
circlip. ‒ → Unbolt cover -A- with Torsen
differential from gearbox cover -B-.
‒ Detach spring from drive pinion.
‒ Then unbolt gearbox cover -B- from
gearbox housing -C-. Page 4 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Remove bolts (arrows) and pull
out the multi-function sender. ‒ → Remove relay shaft bolts (arrows). Page 5 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Unscrew detent segment (arrow)
and swivel it out. ‒ → The input shaft -A-, the drive
pinion -B-, the relay shaft -C-, the
selector rods -D- with the selector
shaft and the selector forks -E-
should be carefully pulled out
together. Installing Page 6 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

Note: If the input shaft ball bearing, the input shaft or the gearbox housing are renewed, it is
necessary to re-determine the thickness of
the circlips for the input shaft =>Page 35-23, adjusting input shaft.
‒ → Swing the gearbox housing into
the position shown.
‒ The components listed below can
then be fitted more easily. ‒ → Put the input shaft -A-, the drive
pinion -B-, the relay shaft -C-, the
selector rods -D- with the selector
shaft and the selector forks -E-
together.
‒ Install these components together
into the gearbox housing.
Note:
Relay shaft -C- and the selector shaft can
also be retrofitted =>next page, Fig. N34-
0585 and Fig. V34-2120. ‒ → Turn gearbox housing and
engage 3rd gear (direction of arrow). Page 7 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Now install relay shaft -A-.
‒ Insert selector shaft -B- sideways
onto bore in gearbox housing and
assemble into mounting eye.
‒ Then turn the selector shaft carefully
in direction of arrow. ‒ → Then insert the detent segment
and bolt it tight (arrow). Page 8 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Screw in relay shaft bolts (arrows) ‒ Replace O-ring for multi-function
sender.
‒ → Carefully insert multi-function
sender and tighten (arrows). ‒ → Check that dowel sleeves for
gearbox cover -A- are fitted in
gearbox housing -B- (arrows).
‒ Apply thin coat of sealant AMV 188
001 02 to sealing surfaces.
‒ Fit gearbox cover onto gearbox
housing. ‒ → Check that dowel sleeves for Page 9 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

cover -A- are fitted in gearbox cover -
B- (arrows).
‒ Fit spring -C-.
‒ Apply thin coat of sealant AMV 188
001 02 to sealing surfaces.
‒ Fit cover with Torsen differential -A-
on gearbox cover -B-. ‒ → Fit rear input shaft ball bearing
circlip (arrow).
‒ Push the ball bearing onto the input
shaft.
‒ Installation position: closed
side of ball cage faces
towards gearbox housing ‒ → Press in ball bearing:
‒ Push thrust pad -A- of pressing-in
tool onto input shaft.
‒ Position pressing-in tool behind
splines for clutch plate.
‒ Screw in the bolts -B- until they make contact.
‒ The bolts bear against the
indentations in thrust pad -A-. ‒ Press in ball bearing onto its seat by
alternately tightening the bolts (1/2
turn at a time). ‒ → Now fit the front circlip -D- for the Page 10 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2