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

2010 Tube

t	Thrust block -T10083-

t	Thrust plate -T10084 A-

t	-1-Internal puller 30...37 mm, e.g. -Kukko 21/5-

t	-4-Counter support, e.g. -Kukko 22/1-

t	Refer to technical data when installing new gears → Chapter.

t	Lubricate all bearings, selector gears and synchro-rings on input shaft with gear oil before installing.

t	Do not interchange synchro-rings. When re-using synchro-rings, always fit on the same selector gear.

1 -

Circlip

q	Always renew

q	Determining thickness → Anchor

2 -	Locking collar with synchronising hub for 5th gear

q	Removing and installing → Chapter

q	Dismantling → Fig.

q	Assembling 5th gear locking collar/synchronising hub → Fig. → Fig.

q	Installation position → Fig.

3 -	5th gear synchro-ring

q	Checking for wear → Fig.

4 -	5th speed selector gear

5 -	Needle bearing

q	For 5th gear

q	Renew together with → Item

6 -

Sleeve

q	For 5th gear needle bearing

q	Renew together with → Item

q	Press off with bearing mounting/grooved ball bearing → Fig..

q	Pressing on → Fig.

7 -	Gearbox housing

8 -	Bearing mounting with grooved ball bearings

q	Only renew grooved ball bearings together with bearing mounting.

q	If bearing mounting is separated from gearbox housing, it must always be renewed

q	Pressing off → Fig.

q	Pressing on → Fig.

9 -	Input shaft

10 -	Needle bearing

q	For 3rd gear

11 -	3rd speed selector gear

12 -	3rd gear synchro-ring

q	Checking for wear → Fig.

13 -	Locking collar with synchronising hub for 3rd and 4th gear

q	Press off with 3rd speed selector gear → Fig.

q	Dismantling → Fig.

q	Installation position: Locking collar/synchronising hub → Fig.

q	Assembling → Fig.

q	Pressing on → Fig.

14 -	4th gear synchro-ring

q	Checking for wear → Fig.

15 -	4th speed selector gear

16 -

Sleeve

q	For 4th gear needle bearing

q	Renew together with → Item

q	Press off with 3rd speed selector gear → Fig.

q	Pressing on → Fig.

17 -	Needle bearing

q	For 4th gear

q	Renew together with → Item

18 -	Thrust washer

19 -	Inner race for roller bearing

q	Pressing off → Fig.

q	Pressing on → Fig.

20 -

Circlip

q

Renew

q	Determining thickness → Fig.

21 -	Roller bearing

q	With circlip

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Installation position: Circlip in bearing faces towards input shaft

22 -	Clutch housing

23 -

Spring

q	Installation position → Fig.

24 -	Locking collar for 3rd and 4th gear

25 -	Synchronising hub for 3rd and 4th gear

26 -	Locking pieces (3x)

27 -

Spring

q	Installation position → Fig.

28 -	Locking pieces (3x)

29 -	5th gear synchronising hub

30 -	5th gear locking collar

31 -	Check ring

q	Prevents locking pieces from moving out

q	Removing → Fig.

q	Installing → Fig.

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.

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. –  Insert centralising pins in thrust piece -T10081- into bores in input and output shafts.

Pressing off roller bearing inner race –  Remove circlip. –  Press off inner race of roller bearing together with the following components: t  Thrust washer t  4th speed selector gear with needle bearing t  Locking collar/synchronising hub for 3rd and 4th gears t  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 and 5th gear	1.1 ... 1.7 mm	0.5 mm

Pressing on 3rd and 4th gear synchronising hub with locking collar

Pressing on sleeve -A- for 4th gear needle bearing –  After pressing on sleeve -A-, install 4th gear needle bearing with selector gear for 4th 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 circlip from table.   Note Select locking pieces from → Electronic parts catalogue.