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Home >> Audi >> 2004 >> TT Coupe (8N3) L4-1.8L Turbo (AWP) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> 02M 5/6 Speed Manual AWD >> Disassembly and Assembling >> Assembly Sequence

Assembly Sequence


Assembly sequence

Disassembling and assembling transmission housing, shift mechanism, input shaft, pinion shafts, differential, angled transmission and shift rods





Special tools and equipment
^ VW 309 holding plate
^ VW 313 holding fixture
^ VW 353 transmission support
^ 30 21 sleeve
^ T40008 pressure piece

Special tools and equipment





^ V.A.G 1331 torque wrench
^ V.A.G 1332 torque wrench





^ V.A.G 1669 hex extension SW 6 mm

Disassembling





- Secure transmission to mounting block with bolts - arrows -.
- Rotate transmission in mounting block with oil drain plug facing down.
- Place catch basin underneath.





- Drain transmission oil from manual transmission and angled transmission.
- Remove bolt for right drive flange using VAG1669 or hexsocket 6 mm (locally available).

Notes: Right drive flange remains in angled transmission.

- Removing four connecting bolts (only 3 are shown in Fig.) angled transmission/transmission - arrows -.
- Push angled transmission from transmission.





- Remove slave cylinder with release bearing - arrows -.





- Bring selector shaft into neutral position.
- Remove reverse light switch - 1 -.
- Remove hex head bolts -2- for selector shaft cover - A -.
- Carefully pull off cover.
- Remove securing bolt -3- for selector shaft shift gate.
- Afterward, remove bolts -4- and press shift cover - B - off of transmission housing.
- Pull selector shaft from transmission housing.





- Remove left drive flange.
- Removing securing bolts - A - for transmission housing at clutch housing in area of differential.





- Remove bolts - B -, from clutch housing which serve to secure transmission housing.

Notes: Hex head bolt - arrow - is located outside the securing flange. It is installed with a washer.





- Remove transmission housing and if necessary, pry off at overlapping ribs all around housing alternating sides using mounting lever while making sure sealing edges are not damaged.
- Swing input shaft in direction of arrow and remove.





- Remove speed sensor.
- Together with the help of a 2nd technician, pull off differential - 1 -, pinion shafts -2- and - 3 -, reverse shaft -4- as well as shift rods -5- carefully from clutch housing.
- Drive out O-ring for input shaft with 30 21 sleeve.

Assembling





- Insert differential - 1 -.





- Insert pinion shaft 5th/6th and reverse gear -2- together with shift fork reverse gear, shift rod 5th/6th gear -3- and reverse shaft - 4 -.
- As shown in illustration, take pinion shaft 1st to 4th gear -3- with shift rods -5- in right hand.
- Lift differential somewhat with left hand.
- At the same time a 2nd technician slightly lifts the pinion shaft 5th/6th gear and reverse gear -2- together with reverse shaft - 4 -.
- Now insert pinion shaft 1st to 4th gear in direction of arrow.
- The splining of the pinion shafts and axle drive wheel/differential must match up.





- Now insert both shafts into their bearing seats together with 2nd technician.
- Insert input shaft into clutch housing and swing in - arrow-.
- Install transmission housing. Install selector shaft as follows:





- Bring shift rods into neutral position.
- Install selector shaft - 1 -.
- Orient selector shaft so that the shift fingers are inserted into the shift rods 34-84.
- While doing so, align lower bearing for selector shaft through hole for cover (arrow).
- Bolt cover - A - with a bolt -2- M8 x 60 mm to lower bearing for selector shaft - 1 -.





- Tighten bolts for cover - A - by hand, alternating sides (1/2 rotation).
- Remove bolt -2- and instead, insert and tighten original bolt by hand.
- Install shift cover - B - for selector shaft and tighten hex head bolt -4- with tightening torque.
- Now tighten hex head bolts for cover.
- Insert securing bolt -3- for selector shaft shift gate with adhesive D 000 600 A2.
- Install reverse light switch.
- Install complete left drive flange




- Install speed sensor.
- Drive in input shaft sealing washer.
- Install slave cylinder with release bearing.

Install angled transmission as follows:





- Always replace and lightly lubricate rings for sealing angled transmission/manual transmission (arrow A) and rings for sealing oil supply sleeves (arrow B and C).
- Push angled transmission against manual transmission, while joining by centering splining of the input shaft/angled transmission with connecting sleeve/differential.
- Also bring splining of right drive flange and differential bevel gear into agreement and if necessary, turn drive flange.
- With correct splining and centered guide, the angled transmission slides against the manual transmission up to stop.
- Do not pull angled transmission against manual transmission via the bolts, since the angled transmission can be cant and the securing sleeve can break off.





- Tighten four connecting bolts (only 3 are shown in Fig.) for angled transmission/transmission - arrows -.
- Secure bolt for right drive flange using VAG1669 or 6 mm hex socket (locally available) and secure against turning using drift.
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