Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft (pinion shaft)

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust pad -VW 512-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Press tool -VW 407-

t	Drift sleeve -41 - 501-

t  Thrust plate -VW 402-

t  Tube -VW 516-

t  Installing ring -2003/3-

t  -1-Internal puller -Kukko 21/6- t  -3-Splitter -Kukko 17/2- t  -4-Counter-support -Kukko 22/2-

t	Refer to technical data → Chapter when installing new gears or a new output shaft.

t	Always renew both tapered roller bearings together.

t	Do not over-stretch circlips. Always renew circlips which have been damaged or over-stretched.

t	Carry out output shaft adjustment → Chapter if the clutch housing, output shaft (final drive gear set) or tapered roller bearings have been renewed.

1 -	Gearbox housing cover

2 -	5th gear wheel retaining ring

3 -	Thrust washer

4 -	5th gear wheel

q	Removing and installing → Chapter

5 -	Gearbox housing

6 -	Needle bearing

q	Removing and installing → Item

7 -	4th gear wheel retaining ring

8 -	4th gear wheel

q	Installation position → Fig.

9 -	3rd gear wheel retaining ring

q	Re-determining thickness → Chapter

10 -	3rd gear wheel

q	Installation position → Fig.

q	Adjusting axial clearance → Chapter

11 -	2nd speed selector gear

12 -	Needle bearing for 2nd speed selector gear

q	Pulling off inner race → Chapter

q	Pressing on inner race → Chapter

13 -	2nd gear synchro-ring

q	Checking for wear → Fig.

14 -	Locking collar with synchronising hub for 1st and 2nd gear

q	Assembling locking collar/synchronising hub → Fig. and → Fig.

q	Removing and installing → Chapter

15 -	1st gear synchro-ring

q	Checking for wear → Fig.

q	Identification → Fig.

16 -	1st speed selector gear

17 -

Spring

18 -	Locking collar

19 -	Synchronising hub

20 -	Locking pieces

q

3x

21 -	Needle bearing

q	For 1st gear

22 -	Thrust washer

q	Installation position → Chapter

23 -	Clutch housing

24 -

Shim

q	For output shaft

q	Table of adjustments → Chapter

25 -	Small tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

26 -	Small tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

27 -	Output shaft

q	Is paired with final drive gear, always renew together as a set

q	Adjusting → Chapter

28 -	Large tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

29 -	Bearing mounting

q	With large tapered roller bearing outer race and stop for reverse gear wheel

q	Only renew outer race together with large tapered roller bearing and bearing mounting

30 -

Bolt

q	25 Nm and turn 90° further

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
1st and 2nd gear	1.1 ... 1.7 mm	0.5 mm

Identifying 1st gear synchro-ring Identification: 1 tooth missing -arrow- at 3 points. This synchro-ring must only be fitted to 1st gear.

Assembling 1st and 2nd gear locking collar and synchronising hub Installation position of synchronising hub: Identification groove on face -arrow- faces toward outer splines of locking collar. –  Push locking collar over synchronising hub. Recesses for locking pieces in synchronising hub and locking collar must align.

Assembling 1st and 2nd gear locking collar/synchronising hub –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Pulling out small tapered roller bearing outer race A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2-   Note Position installing ring -2003/3- on the mounting surface for the bearing mounting to prevent the legs of counter-support from damaging the clutch housing.

Pressing in small tapered roller bearing outer race

Pressing off small tapered roller bearing inner race A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Inner race can also be pulled off using tapered roller bearing puller -V.A.G 1582- and grip -V.A.G 1582/5-.

Pressing off large tapered roller bearing inner race A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Inner race can also be pulled off using tapered roller bearing puller -V.A.G 1582- and grip -V.A.G 1582/7-.

Heating small and large tapered roller bearing inner race to about 100°C, fitting and pressing home