Audi Workshop Service and Repair Manuals

Servicing bearing plate

Special tools and workshop equipment required

t	Press tool -VW 408 A-

t	Guide pin -10-15-

t	Installing tool -30-504-

t	-1-Internal puller -Kukko 21/2-

t	-2-Counter-support -Kukko 22/1-

Bearing plate - exploded view of components

Observe the general repair instructions → Chapter.

1 -	Bearing plate

q	If renewing, re-determine shim “S4”

2 -	Outer race for tapered roller bearing for pinion shaft

q	Driving out → Fig.

q	Pressing in → Fig.

q	If renewing, re-determine shim “S4”

3 -

Shim “S4”

q	Table of adjustments →

q	Re-determining → Chapter

4 -	Roller bearing for input shaft

q	Pressing out → Fig.

q	Pressing in → Fig.

q	Measuring installation depth → Fig.

5 -	Ball sleeves

q	For selector shafts

q	Removing and installing → Fig.

q	Renew after removing

6 -	Bolt, 35 Nm

q	For relay lever

7 -	Dowel pin (7 x 28)

q	Press in flush

8 -	Selector gear for reverse gear

9 -	Synchro-ring for reverse gear

q	With locking pins

q	Checking for wear → Fig.

q	Installation position: flat on circumference of synchro-ring faces towards input shaft → Anchor

10 -

Spring

q	Installation position: hook single angled end into recess on synchro-ring. Turn double angled end anti-clockwise and insert into opening on bearing plate.

11 -	Shaft for reverse selector gear

12 -	Retaining plate

q	Installation position: chamfers of holes for locking pins of synchro-ring face towards bearing plate → Anchor

13 -	Spring clip

14 -	Bolt, 25 Nm

q	Self-locking

q

Renew

15 -	Relay lever for reverse gear

16 -	Follower for reverse gear

q	Pulling out ball sleeve → Fig.

q	Driving in ball sleeve → Fig.

17 -	Selector rod for 5th and 6th gear

q	Renew only complete with follower → Item

Removing and installing ball sleeves for selector rods –  Install ball sleeve with the inscribed side (thicker metal) facing the drift. l  Dimension -a- = 2.5 mm.

Checking synchro-ring for wear –  Press synchro-ring onto tapered seats of the gear wheel. –  Check gap -a- with a feeler gauge. l  Dimension, new: 0.75 ... 2.3 mm. l  Wear limit 0.2 mm.

Pulling ball sleeve out of follower for reverse gear A -  Counter-support -Kukko 22/1- B -  Internal puller 14.5 ... 18.5 mm -Kukko 21/2-

Driving ball sleeve flush into follower for reverse gear –  Install ball sleeve with the inscribed side (thicker metal) facing the drift.

Pressing roller bearing for input shaft out of bearing plate

Pressing roller bearing for input shaft into bearing plate –  Measuring insertion depth → Fig..

Measuring insertion depth of roller bearing for input shaft l  Insertion depth -a-= 7 mm.