Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Tube -VW 422-

t	Spacer sleeve -VW 472/2-

t	Tube -VW 516-

t	Extension -30 - 23-

t	Drift sleeve -30 - 100-

t	Thrust piece -T10080-

t	Thrust piece -T10081-

t	Thrust block -T10083-

t	Thrust plate -T10084 A-

t	-1-Internal puller -Kukko 21/5-

t	-4-Counter-support -Kukko 22/2-

Pulling roller bearing out of clutch housing –  When pulling out, compress circlip -arrow- for roller bearing using pliers -C-. A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 30 ... 37 mm, e.g. -Kukko 21/5-

Pressing roller bearing into clutch housing –  Support clutch housing using tube -VW 415 A- (not visible in diagram) directly under bearing mounting. –  When pressing in, compress circlip -arrow- for roller bearing using pliers -A-. –  Remove the pliers before the roller bearing is in its final position. The circlip must engage in the groove in the clutch housing. If 5th gear wheel -A- could not be removed by hand:

Pressing off bearing mounting with grooved ball bearings and 5th gear wheel -A- –  Slide locking collar for 1st and 2nd gear onto 2nd gear. –  Slide in thrust plate -T10084 A- sideways until it contacts input shaft. If 5th gear wheel could be removed by hand:

Pressing off bearing mounting and grooved ball bearings –  Slide locking collar for 1st and 2nd gear onto 2nd gear. –  Slide in thrust plate -T10084 A- sideways until it contacts input shaft. –  Remove circlip.

Pressing off roller bearing inner race –  Press off roller bearing inner race together with: thrust washer, 4th speed selector gear with needle bearing, locking collar and synchronising hub for 3rd and 4th gear and 3rd speed selector gear.

Dismantling and assembling 3rd and 4th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. The deeper recesses -arrow A- for the locking pieces in the synchronising hub must align with the recesses -arrow B- in the locking collar.

Assembling 3rd and 4th gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces in the deeper slots -arrows- and install springs off-set by 120°. Angled end of spring must locate in hollow locking piece.

Installation position of 3rd and 4th gear locking collar/synchronising hub The groove on the top -arrow- points towards 4th gear.

Checking synchro-ring for wear –  Press synchro-ring onto tapered seat on selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation depth	Wear limit
3rd, 4th, 5th and 6th gear	1.1 ... 1.7 mm	0.5 mm

Pressing on 3rd and 4th gear synchronising hub with locking collar Installation position: higher collar faces 3rd speed selector gear.

Pressing on sleeve -A- for 4th gear needle bearing –  After pressing on sleeve -A-, install 4th gear needle bearing with 4th speed selector gear and thrust washer.

Pressing on roller bearing inner race -A-

Determining thickness of circlip –  Insert a 2.0 mm thick circlip -A- in groove of input shaft and press upwards -arrow-. –  Measure gap between inner race -B- and fitted circlip -A- using feeler gauge -C-. –  Remove circlip fitted for measurement. –  Select required circlip from table and install. For part numbers, refer to → Electronic parts catalogue. The following circlips are available:

Measured value (mm)	Circlip thickness (mm)	Axial clearance (mm)
0.05 … 0.14	2.0	0.05 … 0.15
0.15 … 0.24	2.1	0.05 … 0.15
0.25 … 0.34	2.2	0.05 … 0.15
0.35 … 0.44	2.3	0.05 … 0.15
0.45 … 0.51	2.4	0.05 … 0.10

Pressing on bearing mounting with grooved ball bearing –  Heat bearing mounting to 100°C (maximum) before pressing on.   WARNING Wear protective gloves.

Pressing on sleeve -A- for 5th gear needle bearing

Dismantling and assembling 5th/6th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. The deeper recesses -arrow A- for the locking pieces in the synchronising hub must align with the recesses -arrow B- in the locking collar.

Assembling 5th/6th gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces in the deeper recesses -arrows- and install springs 120° off-set. l  Angled end of spring must locate in hollow locking piece.