Audi Workshop Service and Repair Manuals

1st gear synchromesh modified as of gearbox build date 02 05 0

The following components are only fitted from this gearbox build date onwards, or were modified: t  -A- Inner ring t  -B- Outer ring t  -C- Synchro-ring With additional slots -arrows 4- for lugs -arrows 1- on inner ring -A-. t  1st speed selector gear With additional slots -arrows 3- for lugs -arrows 2- on outer ring -B-.   Note t  The same inner ring, outer ring and synchro-ring are also installed on 2nd gear. t  If components are not being renewed, make sure they are re-installed on the same gear.

Installation position of inner ring, outer ring and synchro-ring for 1st gear: –  Place inner ring -A- on 1st speed selector gear. The angled lugs -arrows 1- point towards outer ring -B-. –  Fit outer ring -B-. The lugs -arrows 2- lock in the slots -arrows 3- on the selector gear. –  Fit synchro-ring -C-. The slots -arrows 4- locate on the lugs -arrows 1- of inner ring -A-.

Checking inner ring for 1st gear for wear –  Press inner ring onto tapered seat on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation depth	Wear limit
1st gear	0.75 ... 1.25 mm	0.3 mm

Checking 1st gear synchro-ring and outer ring for wear –  Press synchro-ring, outer ring and inner ring onto tapered seat on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation depth	Wear limit
1st gear	1.2 ... 1.8 mm	0.5 mm

Assembling locking collar and locking pieces with synchronising hub for 1st and 2nd gear 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece After introduction of the modified 1st gear synchromesh, the collar is the same width on both sides of the synchronising hub. The shoulder on one side is chamfered -arrow B-. When assembled, the chamfer on the shoulder of the synchronising hub and the external teeth on the locking collar -arrow A- face in the same direction. The recesses for the locking pieces on synchronising hub and locking collar -arrow C- must align.

Installation position of 1st and 2nd gear locking collar/synchronising hub Splines on locking collar -arrow- point to splines for 3rd/4th gear synchronising hub -A-. –  Remove and install 1st gear synchronising hub as described above.