Audi Workshop Service and Repair Manuals

Installing 5th gear l  Please ensure that the support bridge -30-211A- and support bridge -T10323- are fitted.

Installation position of 5th gear wheel The groove running round the gear wheel -arrow- faces to the gearbox housing.

–  Drive on 5th gear wheel.

Checking 5th gear synchro-ring –  Before re-installing selector gear and synchro-ring for 5th gear, press the synchro-ring onto the tapered seat of the selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation depth	Wear limit
5th gear	1.1…1.7 mm	0.5 mm

–  Install 5th speed selector gear with needle bearing. –  Fit 5th gear synchro-ring on selector gear. –  If previously dismantled, assemble 5th gear synchro-hub/locking collar before installing → Fig..

Installation position of 5th gear synchro-hub/locking collar The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchro-hub -arrow 2- face the gearbox housing. The retainers in the synchro-hub -arrow 3- align with the cast locking pieces on the synchro-ring (-arrows- in the illustration below).

5th gear synchro-ring with cast locking pieces -arrows- –  Cover all openings with a cloth to prevent dirt etc. from entering the gearbox.

–  Knock on 5th gear synchro-hub.   Note When driving on, ensure clearance for synchro-ring.

–  Loosen support for input shaft.   WARNING Wear protective gloves. –  Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing synchro-hub and 5th gear wheel. Otherwise there is a risk that the bolts will shear off. –  Screw in securing bolts for synchro-hub and 5th gear wheel.

Installation position of dished springs for securing bolts for 5th gear wheel and synchro-hub Concave side -arrows- faces 5th gear. –  Tighten securing bolts for synchro-hub and 5th gear wheel to specified torque → Chapter.

–  Tighten bolts -A- for synchro-hub and 5th gear wheel to specified torque → Item; to do this select 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  After engaging both gears the input shaft and output shaft are locked; the synchro-hub and gear wheel cannot turn. The two bolts can now be tightened. –  Install 5th gear selector fork.

Adjusting 5th gear –  Engage 5th gear. Loosen bolt -1-. Press locking collar and selector jaws in direction of arrow, then tighten bolt -1- to 25 Nm. l  Check adjustment: It should not be possible to slide a 0.2 mm feeler gauge between locking collar and selector gear. Repeat adjustment if necessary. –  Disengage 5th gear. Locking collar should now be in the neutral position. Synchro-ring should move freely. –  Select all gears. –  Install gearbox housing cover → Chapter. –  Install release bearing guide sleeve → Chapter. –  Install clutch release lever and release bearing → Chapter. –  Fill up gear oil; capacities → Chapter.