Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft and hollow shaft

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 411-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support rails -VW 457-

t	Multi-purpose tool -VW 771-

t	Installing ring -2003/3-

t	Punch -3013-

t	Thrust pad -3062-

t	Press tool -3118-

t	Drift -3138-

t	Hot air blower -V.A.G 1416-

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

t	-3-Splitter -Kukko 17/2-

Exploded view

t	When installing new gears or final drive gear set → Chapter „Code letters, allocation, transmission ratios, capacities“.

t	Adjustment work is required when renewing the parts marked with 1) → Anchor.

1 -	Gearbox housing

q	Servicing → Chapter

2 -

Shim “S3”

q	Table of adjustments → Anchor

3 -	Outer race for large tapered roller bearing 1)

q	Pulling out → Fig.

q	Pressing in → Fig. and → Fig.

4 -	Pinion shaft 1)

q	Paired with crown wheel (final drive gear set)

q	Adjusting pinion shaft and crown wheel → Chapter

5 -	Needle roller bearing for flange shaft/pinion shaft

q	Pulling out → Fig.

q	Driving in → Fig.

6 -	Inner race for large tapered roller bearing 1)

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

7 -

Circlip

q	Re-determining thickness → Fig.

8 -	Flange ring

q	Installation position → Anchor

9 -	Tapered rollers

q

23 x

q	Installation position → Anchor

10 -	Support ring

q	Installation position → Anchor

11 -	Corrugated spring

12 -	Needle bearing for pinion shaft/hollow shaft

q	Lubricate with gear oil before installing

13 -	Hollow shaft with 3rd and 4th gear wheels 1)

14 -	Needle bearing for 2nd speed selector gear

q

Split

q	Lubricate with gear oil before installing

15 -	2nd speed selector gear

q	Pressing off → Fig.

q	Before installing, fit spring and slide needle bearing onto hollow shaft

q	After installing, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)

16 -	Synchro-ring for 2nd gear

q	With molybdenum coating

q	Checking for wear → Fig.

17 -	Synchronising hub for 1st and 2nd gear

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Installation position: flush hub towards 2nd speed selector gear

18 -

Circlip

q	Removing and installing → Fig.

q	Re-determining thickness → Fig.

19 -	Shim for needle bearing for 1st speed selector gear

q	Removing and installing → Fig.

20 -	Locking collar for 1st and 2nd gear

q	Installation position: splines for reverse gear towards synchro-ring for 2nd gear

21 -	Synchro-ring for 1st gear

q	Checking for wear → Fig.

22 -	Needle bearing for 1st speed selector gear

q	Lubricate with gear oil before installing

23 -	1st speed selector gear

q	Before installing, insert spring → Fig.

q	After pressing on → Item, check axial clearance (0.15 ... 0.35 mm)

24 -	Inner race for small tapered roller bearing 1)

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

25 -	Outer race for small tapered roller bearing 1)

q	Driving out → Fig.

q	Pressing in → Fig.

26 -

Shim “S4”

q	Table of adjustments → Anchor

27 -	Intermediate housing 1)

q	Servicing → Chapter

28 -	6th gear wheel

q	Pressing off → Anchor

q	Pressing on → Anchor

q	Installation position: shoulder towards inner race for small tapered roller bearing

29 -	Spacer sleeve

30 -

Shim

q	Re-determining thickness → Anchor

31 -	5th gear wheel

q	Pulling off → Anchor

q	Driving on → Anchor

32 -	Circlip for 5th gear wheel

q	Re-determining thickness → Anchor

33 -

End cover

q	Servicing → Chapter

Checking synchro-ring for wear –  Press synchro-ring into locking collar and measure gap -a- with a feeler gauge at positions -A-, -B- and -C-. –  Add the 3 measured values together and divide by 3. l  The average gap must not be less than 0.5 mm.

Checking synchro-ring with molybdenum coating for wear   Note Friction surface of intact synchro-ring has a graphite-grey, slightly porous appearance. –  Clean synchro-ring and make sure that friction surface is free of oil. If very shiny areas -A- have formed on friction surface or if brass-coloured surface underneath is already visible: –  Renew synchro-ring.

Pulling out outer race for large tapered roller bearing l  Stepped side of thrust pad -3062- rests against the outer race

Heating gearbox housing to insert outer race for large tapered roller bearing   WARNING Wear protective gloves. –  Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 °C, with a hot air blower.

Installing outer race for large tapered roller bearing in gearbox housing and pressing home   WARNING Wear protective gloves. –  Insert outer race only after heating gearbox housing and press home under workshop press for 1 ... 2 minutes until heat exchange has taken place.

Pulling out needle bearing for flange shaft/pinion shaft A -  Internal puller 12 ... 14.5 mm -Kukko 21/1-

Driving needle bearing for flange shaft/ pinion shaft in flush

Pressing off inner race for large tapered roller bearing A -  Splitter 22 ... 115 mm -Kukko 17/2-   Note Pressing off destroys bearing.

Pressing on inner race for large tapered roller bearing   WARNING Wear protective gloves. –  Heat inner race to approx. 100 °C, fit in position and press onto stop so there is no axial clearance.

Determining circlip for large tapered roller bearing for pinion shaft –  Determine the thickest circlip that can still just be fitted. –  Select required circlip thickness from following table:

Available circlips - Thickness in mm 1)
2.34	2.40	2.46
2.36	2.42	2.48
2.38	2.44
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit circlip.

Pressing off inner race of small tapered roller bearing for pinion shaft together with 1st speed selector gear   Note Do not press off together with 1st and 2nd gear synchronising hub and 2nd speed selector gear.

Pressing on inner race of small tapered roller bearing for pinion shaft together with 1st speed selector gear –  Install circlip, shim for 1st speed selector gear, synchro-ring for 1st speed, and 1st speed selector gear with spring and needle bearing.   WARNING Wear protective gloves. –  Heat inner race to approx. 100 °C, fit in position and press onto stop so there is no axial clearance. l  With shoulder of press tool -3118- facing downwards, press only onto bearing inner race. l  Position stepped shoulder of tube -VW 415 A- facing up towards press tool -VW 412-. –  Check axial clearance of 1st speed selector gear after pressing on.

Removing and installing circlip for synchronising hub and shim for 1st speed selector gear –  First take out shim -A-, then circlip -B- when removing. –  First fit circlip -B-, then shim -A- when installing.

Pressing off 2nd speed selector gear with synchronising hub for 1st and 2nd gear –  Take off locking collar for 1st and 2nd gear and synchro-ring for 1st gear. –  Remove shim and circlip for synchronising hub –  Press off 2nd speed selector gear together with synchronising hub for 1st and 2nd gear.   Note Do not press off together with 1st speed selector gear and inner race for small tapered roller bearing.

Fitting 2nd speed selector gear, pressing on synchronising hub for 1st and 2nd gear –  Install needle bearing (split), selector gear with spring and synchro-ring for 2nd gear. –  Lubricate needle bearing with oil.   WARNING Wear protective gloves. –  Heat synchronising hub to approx. 100 °C, fit in position and press onto stop so there is no axial clearance. l  Position tube -VW 415 A- with shoulder towards synchronising hub. l  The collar of press tool -3118- points towards press tool -VW 412-.

Determining thickness of circlip for synchronising hub for 1st and 2nd gear –  Determine the thickest circlip that can still just be fitted. –  Select required circlip thickness from following table:

Available circlips - Thickness in mm 1)
1.90	1.96	2.02
1.93	1.99
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit circlip onto synchronising hub in direction of -arrow-.

Driving out outer race for small tapered roller bearing

Pressing in outer race for small tapered roller bearing –  Insert shim “S4” into intermediate housing behind bearing seat. l  The collar of press tool -3062- points towards press tool -VW 407-. –  Press in small tapered roller bearing outer race as far as stop.