Audi Workshop Service and Repair Manuals

Circlips available

Measured value (mm)	Circlip thickness (mm)	Axial clearance (mm)
0.05 ... 0.10	2.0	0.05 ... 0.15
0.15 ... 0.20	2.1	0.05 ... 0.15
0.25 ... 0.30	2.2	0.05 ... 0.15
0.35 ... 0.40	2.3	0.05 ... 0.15
0.45 ... 0.50	2.4	0.05 ... 0.10

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

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

Detaching check ring –  Unclip hooks -A- of check ring from synchronising hub using a screwdriver.

Dismantling and assembling 5th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking piece 3 -  Synchronising hub  -  Installation position: the groove on the top -arrow A- and the wide collar -arrow B- face the 5th gear 4 -  Locking collar 5 -  Check ring –  Push locking collar over synchronising hub. The deeper recesses -arrow C- for the locking pieces in the synchronising hub must align with the recesses -arrow D- in the locking collar.

Assembling 5th 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. Angled end of spring must locate in hollow locking piece.

Installing check ring –  Press check ring onto tube 2010. –  Insert check ring together with tube 2010 into 5th gear synchronising hub/locking collar (observe installation position → Fig.). Hooks -arrow 1- engage in slots -arrow 2- for locking pieces in synchronising hub. –  Push check ring downwards until hooks engage.