Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 5th, 6th and reverse gear

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 408 A-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Press tool -VW 433-

t	Press tool -VW 454-

t	Support rails -VW 457-

t	Support plate -VW 801-

t	Press tool -VW 431-

t	Installing sleeve -VW 455-

t	Thrust pad -VW 510-

t	Tube -VW 516-

t	Tube -VW 519-

t	Thrust plate -30 - 11-

t	Thrust plate -40 - 105-

t	Drift sleeve -40 - 20-

t	Thrust piece -2050-

t	Tube -3296-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t  Adapter -V.A.G 1582/7-

t  -1-Internal puller -Kukko 21/7- t  -3-Splitter -Kukko 17/2- t  -4-Counter-support -Kukko 22/2-

Pulling out tapered roller bearing outer race A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-   Note After pulling out, check shim for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing –  Fit shim below outer race. –  Place drift sleeve -40 - 20- directly under bearing mounting to support clutch housing.

Pulling off tapered roller bearing inner race –  Remove circlip. –  Before setting up puller, position press tool -VW 431- and thrust plate -40 - 105- on output shaft.

Pressing off 5th and 6th gear synchronising hub/locking collar with 6th speed selector gear –  Remove circlip before pressing off.

Pressing off sleeve -A- with reverse selector gear –  Remove circlip before pressing off.

Pressing off reverse gear synchronising hub –  Remove circlip before pressing off. A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pulling off tapered roller bearing inner race –  Before applying puller, place thrust plate -30 - 11- on output shaft.

Installation position of reverse gear synchronising hub l  Stop -arrow A- for reverse gear locking collar faces towards gear teeth on output shaft -arrow B-.

Pressing on reverse gear synchronising hub –  Then install circlip.

Pressing on sleeve -A- l  Installation position: Wide shoulder faces towards reverse selector gear –  Then install circlip.

Checking 5th and 6th gear synchro-ring for wear –  Push synchro-ring against tapered surface on selector gear and measure gap -a- with feeler gauge.

Original dimension	Wear limit
1.0 ... 1.7 mm	0.5 mm

Dismantling and assembling 5th and 6th gear locking collar/synchronising hub –  Take off springs -1- before dismantling. 2 -  Locking piece 3 -  Locking collar 4 -  Synchronising hub –  To assemble, slide locking collar over synchronising hub. l  Installation position: The smaller slots -arrow A- in the synchronising hub should be in line with the slots -arrow B- in the locking collar.

Assembling 5th and 6th gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces and install springs offset at 120°. l  Angled end of spring must locate in hollow locking piece.

Pressing on 5th and 6th gear locking collar/synchronising hub –  Then install circlip.

Pressing on tapered roller bearing inner race –  Then determine thickness of required circlip → Fig. and install circlip.

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it. For part number refer to → Electronic parts catalogue.

Circlip thickness (mm)
1.79	1.83	1.86
1.89	1.92	1.95
1.98

Pressing on tapered roller bearing inner race

Pulling tapered roller bearing outer race out of gearbox housing A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Place thrust piece -2050- directly under bearing mounting to support gearbox housing.