Audi Workshop Service and Repair Manuals

Notes:

• ◆ When installing new gears or a new final drive set (drive pinion and crown wheel)
  =>Technical data, Page 00-3.
• ◆ Adjustments are required when renewing components marked 1) => Adjustment overview, Page 39-28.

• Gearbox housing
• ◆ Servicing
• Shim "S3"
• ◆ Adjustment overview => Page 39-28
• Outer race for large taper roller
  bearing 1)
• ◆ Pulling out => Fig.1
• ◆ Pressing in => Fig.2 and Fig.3

• Drive pinion1)
• ◆ Paired with crown wheel (final drive set)
• Inner race for large taper roller bearing1)
• ◆ Pressing off => Fig.8
• ◆ Pressing on => Fig.9
• ◆ Low friction bearing; do not oil when measuring frictional torque
• 4th speed gear
• ◆ Pressing off => Fig.7
• ◆ Pressing on => Fig.10
• Spacer sleeve
• 3rd speed gear
• ◆ Pressing off together with item 9
  => Fig.6
• ◆ Pressing on => Fig.11

• Inner race for 2nd speed sliding gear
• ◆ Pressing off together with item 8
  => Fig.6
• ◆ Pressing on => Fig.12
• Needle bearing for 2nd speed sliding gear
• ◆ Lubricate with gear oil before installing
• 2nd speed sliding gear
• ◆ Pressing off => Fig.5
• ◆ Before installing, fit spring and slide needle bearing onto hollow shaft
• ◆ After installing, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)
• Synchro-ring for 2nd gear
• ◆ Checking for wear => Fig.35-9
• ◆ Synchro-ring with molybdenum coating

• Synchro-hub for 1st and 2nd gear
• ◆ Pressing off => Fig.5
• ◆ Pressing on => Fig.13
• ◆ Installation position: flush hub towards 2nd speed sliding gear
• Locking collar for 1st and 2nd gear
• ◆ Installation position: groove for selector fork faces towards 1st speed sliding gear
• Synchro-ring for 1st gear
• ◆ Checking for wear => Fig.35-9
• Inner race for 1st speed sliding gear
• ◆ Pressing off => Fig.5
• ◆ Pressing on => Fig.14

• Needle bearing for 1st speed sliding gear
• ◆ Oil with gear oil before installing
• 1st speed sliding gear
• ◆ Before installing, insert spring
  => Fig.35-9
• ◆ After pressing on -item 19-, check axial clearance using a feeler gauge (0.15 ... 0.50 mm)
• Inner race for small taper roller bearing 1)
• ◆ Pressing off=> Fig.4
• ◆ Pressing on => Fig.15
• ◆ Low friction bearing; do not oil when measuring frictional torque
• Outer race for small taper roller bearing 1)
• ◆ Driving out => Fig.16
• ◆ Pressing in => Fig.17

• Shim "S4"
• ◆ Adjustment overview => Page 39-28
• Bearing plate 1)
• ◆ Servicing => Page 34-90
• Circlip
• ◆ Re-determining thickness (5-speed gearbox) => Page 34-67
• ◆ Re-determining thickness (6-speed gearbox) => Page 34-69
• 6th gear wheel
• ◆ Not fitted on 5-speed gearbox
• ◆ Pressing off => Page 34-61
• ◆ Pressing on => Page 34-62
• ◆ Installation position: shoulder towards inner race for small taper roller bearing

• Circlip
• ◆ Re-determining thickness (5-speed gearbox) => Page 34-67
• ◆ Install behind -item 23- on 5-speed gearbox
• ◆ Re-determining thickness (6-speed gearbox) => Page 34-69
• 5th gear wheel
• ◆ Pulling off => Page 34-56
• ◆ Driving on => Page 34-74
• Circlip
• End cover
• ◆ Servicing => Page 34-80

→ Fig.1    Pulling out outer race for large taper roller bearing

• ◆ Stepped side of thrust pad 3062 rests against the outer race

→ Fig.2    Heating gearbox housing in order to fit taper roller bearing outer race

• ‒ Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 °C, with a hot air blower.

→ Fig.3    Inserting outer race for large taper roller bearing in gearbox housing and pressing home

• ‒ Insert outer race only after heating gearbox housing and press home for 1 ... 2 minutes under a repair press until a heat exchange has taken place.

→ Fig.4    Pressing off inner race of small taper roller bearing for drive pinion together with 1st speed sliding gear

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.5    Pressing off 2nd speed sliding gear with locking collar/synchro-hub for 1st and 2nd speed gear and inner race for 1st speed sliding gear

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.6    Pressing off 3rd speed gear together with inner race for 2nd speed sliding gear

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.7    Pressing off 4th speed gear

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

Note:

The 4th speed gear can also be pressed off together with the 3rd speed gear and the inner race for the 3rd speed sliding gear.

→ Fig.8    Pressing off inner race for large taper roller bearing

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

• ◆ Bearing is destroyed when pressing off

→ Fig.9    Pressing on inner race for large taper roller bearing

• ‒ Heat inner race to approx. 100 °C and fit.
• ‒ Press home ensuring there is no axial play.

→ Fig.10    Pressing on 4th speed gear

• ‒ Heat gear to about 100 °C, fit and press home.

• ◆ Installation position: shoulder towards 3rd speed gear

→ Fig.11    Pressing on 3rd speed gear

• ‒ Insert spacer sleeve -arrow-.
• ‒ Heat gear to about 100 °C, fit and press home.

• ◆ Installation position: shoulder towards 4th speed gear

→ Fig.12    Pressing on inner race for 2nd speed sliding gear

• ‒ Heat inner race to approx. 100 °C and fit.
• ‒ Press home ensuring there is no axial play.

→ Fig.13    Fitting 2nd speed sliding gear and pressing on synchro-hub for 1st and 2nd speed gears

• ‒ Oil needle bearing.
• ‒ Fit needle bearing, sliding gear (with spring) and synchro-ring for 2nd speed gear.
• ‒ Heat synchro-hub to approx. 100 °C and fit.
• ‒ Installation position: flush hub towards 2nd speed sliding gear
• ‒ Press home ensuring there is no axial play.

→ Fig.14    Pressing on inner race for 1st speed sliding gear

• ‒ Heat inner race to approx. 100 °C and fit.
• ‒ Press home ensuring there is no axial play.

→ Fig.15    Pressing on small taper roller bearing inner race for drive pinion

• ‒ Oil needle bearing.
• ‒ Fit needle bearing, sliding gear (with spring) and synchro-ring for 1st speed gear.
• ‒ Heat inner race to approx. 100 °C and fit.
• ‒ Press home ensuring there is no axial play.

→ Fig.16    Driving out outer race for small taper roller bearing

→ Fig.17    Pressing in outer race for small taper roller bearing

• ‒ Insert shim "S4" into bearing flange behind bearing seat.
• ‒ Press outer race for small taper roller bearing onto stop.