Audi Workshop Service and Repair Manuals

Renewing gasket for gear actuator Special tools and workshop equipment required t  Gearbox support -VW 353- t  Support plate -VW 309- t  Engine and gearbox support -VAS 6095- or support clamp -VW 313- t  Torque wrench -V.A.G 1410- t  Engine bung set -VAS 6122- t  Strong rubber band t  Bolt M8 x 30 t  Nut M5

Procedure Observe rules for cleanliness: t  Only use lint-free cloths for cleaning, e.g. a „WYPALL X70 / WORKHORSE“ cloth from Kimberly-Clark Professional. t  Place removed parts on a clean surface and cover them over. Use sheeting or lint-free cloths. t  Carefully cover or seal dismantled components if repairs cannot be completed immediately. t  Only install clean components: do not remove replacement parts from packaging until just before installation. –  Remove gear actuator → Chapter. –  Attach support plate -VW 309- to gearbox support -VW 353- and insert in engine and gearbox support -VAS 6095-.   Caution Risk of damage to selector lever valve 2 -N285- The selector lever valve 2 -N285- will be damaged if a bolt -1- longer than M8 x 30 is used. –  Secure gear actuator -2- to gearbox support -VW 353- with bolt -1- (M8 x 30) and tighten to 20 Nm.

–  Seal off open connections -1- with clean plugs from engine bung set -VAS 6122-. –  Place drip tray in position. –  Clean gear actuator. –  Clean cover for gear actuator -2-, housing -3- and connection point -arrow- with brake cleaner. –  Blow off and dry gear actuator with compressed air.

–  Pull selector finger -2- off bellows -1-.   Note

Do not remove bolts -5 and 6- at this stage. –  Remove bolts -1 to 4-.   Note t  Renew bolts. t  The bolts are of different lengths; take care to install in correct positions.

Caution Risk of damage to gear actuator t  The cover for the gear actuator must be secured as shown before removing the bolts -2-. t  The bolts -2- hold the cover for the gear actuator -A- and the potentiometer carrier -B- together. t  If the cover for the gear actuator -A- is separated from the potentiometer carrier -B- it is no longer possible to reproduce the basic setting of the gear actuator, and the complete gear actuator must be renewed. t  It is important to perform the following steps exactly as described. –  Use a strong rubber band -1- to secure cover for gear actuator -A- firmly to potentiometer carrier -B-.

–  Unscrew bolts -2- but leave them inserted in bolt holes.

–  Press cover for gear actuator -A- and potentiometer carrier -B- together by hand and detach.   Note Do not remove the rubber band -1- and the two bolts -2-.

–  Secure one of the two bolts with an M5 nut -1- to prevent it from falling out.   Note t  Do not screw on nut -1- further than 3 threads t  Ensure that the sealing surface is not damaged.

–  Take off gasket -1-. –  Clean sealing surface -2- on gear actuator with a lint-free cloth.   Caution Risk of damage to gear actuator t  No dirt must be allowed to enter the gear actuator. t  Even the slightest amount of dirt can cause a failure of the gear actuator. –  Fit new gasket -1- (dry) onto gear actuator.   Note When the gasket is fitted correctly, all the bolt holes in the gear actuator coincide with the holes in the gasket

–  Take hold of cover for gear actuator -A- and potentiometer carrier -B-, keeping them pressed together by hand.

–  Remove nut -1- and take out bolts. –  Clean sealing surface -3- on cover for gear actuator with a lint-free cloth. –  Fit two new bolts (M5 x 38).   Note The bolts are of different lengths; take care to install in correct positions → Anchor.

–  Fit cover for gear actuator with bolts -2- inserted.

–  Screw in bolts -2- (hand-tight). –  Take off rubber band -1-.

Positions of bolts: t  Bolts -1- and -2-: M5 x 16 t  Bolts -3- and -4-: M5 x 30 t  Bolts -5- and -6-: M5 x 38 –  Screw in new bolts -1 to 4- (hand-tight). –  Using torque wrench -V.A.G 1410-, tighten bolts to 5 Nm in the sequence indicated: -1 to 6-.

–  Check bellows -1- for damage and renew if necessary. –  Pack fresh grease into bellows -1- and selector finger -2- if old grease is dirty or not sufficient → Electronic parts catalogue. –  Engage selector finger -2- in bellows -1-. l  The sealing surface -arrow A- of the bellows must engage all round in the groove -arrow B- on the selector finger.

–  Check sealing washers -arrows 1- for damage and renew if necessary. –  Check ball joints -arrows 2- on selector rod; they must be free of play. –  Fit the gear actuator → Chapter.   Note t  Perform all work and tests required after installation of the gear actuator, including the following: t  Visual inspection of hydraulic system for leakage. t  Check the fluid level in the reservoir for the clutch mechanism and selector mechanism and replenish the fluid → Booklet809. t  Adjust the gear actuator → Chapter.