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Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft > < Output shaft

A4 Mk3

Exploded view - output shaft
   
Exploded view - output shaft
Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft → Chapter
Dismantling and assembling output shaft → Chapter
  Note
t  Refer to technical data when installing new gears or output shaft → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.00.
t  Lubricate all needle bearings and synchro-rings with gear oil before installing.
t  When renewing synchro-rings, renew inner ring, intermediate ring and synchro-ring for the corresponding gear together.
t  If synchro-rings are not being renewed, make sure they are re-installed on the same gear.
1 - Sealing cap
q   With oil guide
q   For output shaft
q   Removing and installing → Chapter
2 - Bolt
q   200 Nm
q   For output shaft
q   Apply locking fluid -AMV 185 101 A1- when fitting
q   To loosen, heat bolt to approx. 80 °C if necessary using hot air blower -V.A.G 1416-
3 - Gearbox housing
4 - Ball bearing
q   For output shaft
q   Removing and installing → Item
5 - Circlip
q   Note installation position → Fig.
6 - Reverse gear synchro-hub
q   Removing and installing → Chapter
7 - Synchro-spring
q   Insert in drilling in reverse gear synchro-hub
8 - Synchro-ring for reverse gear
q   Checking for wear → Fig.
9 - Reverse gear locking collar
q   Installation position → Fig.
10 - Reverse selector gear
q   Installation position → Fig.
11 - Needle bearing
q   For reverse gear
12 - Needle bearing inner race
q   For reverse gear
q   Removing and installing → Chapter
13 - Thrust washer
q   For 1st speed and reverse selector gears
14 - 1st speed selector gear
15 - Inner ring for 1st gear
q   Installation position → Fig.
q   Distinguishing inner rings for 1st and 2nd gear → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
16 - Intermediate ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
17 - Synchro-ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
18 - Needle bearing
q   For 1st gear
19 - Circlip
q   Determining thickness → Anchor
20 - Thrust block
q   3x
q   Installing → Fig.
21 - Synchro-hub for 1st and 2nd gear
q   Installation position → Fig.
22 - Locking collar for 1st and 2nd gear
q   Installation position → Fig.
23 - Synchro-ring for 2nd gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
24 - Intermediate ring for 2nd gear
q   Installation position → Fig.
q   Checking for wear → Fig.
25 - Inner ring for 2nd gear
q   Installation position → Fig.
q   Distinguishing inner rings for 1st and 2nd gear → Fig.
q   Renew if scored or if there are visible traces of wear
26 - 2nd speed selector gear
27 - Needle bearing
q   For 2nd gear
28 - Bearing mounting
q   Carries bearings for input shaft and output shaft in gearbox cover
q   → Item
29 - Roller bearing
q   For output shaft
q   Pressing off → Fig.
q   Pressing on → Fig.
q   Always renew
30 - Output shaft
q   With splines for 5th and 6th gear
31 - 3rd gear wheel
q   Pressing off → Fig.
q   Installation position: high inside collar faces 4th gear
q   Pressing on → Fig.
32 - Spacer sleeve
33 - 4th gear wheel
q   Pressing off → Fig.
q   Installation position: high inside collar faces spur gear → Item
q   Pressing on → Fig.
34 - Gearbox cover
35 - Roller bearing
q   Bearing for spur gear in gearbox cover
q   Removing and installing → Item
36 - Spur gear
q   Drive gear for side shaft / pinion shaft (spur gearing)
q   Removing and installing → Chapter
37 - Circlip
q   Determining thickness → Anchor
q   Fit in annular groove on output shaft

   
Installation position of locking collar -2- and selector gear -1- for reverse gear
l  The pointed teeth -arrow A- of the locking collar -2- point away from the driving teeth -arrow B- of the reverse selector gear -1-.
  A35-10110
Checking synchro-ring for wear
–  Press synchro-ring -E- into locking collar and measure gap -a- at positions -A-, -B- and -C- using depth gauge -D-.
–  Add the measured values and divide by 3.
The determined value should not exceed 0.5 mm.
  A35-10147
Distinguishing inner rings for 1st gear -A- and 2nd gear -B-
-A- The inner ring for 1st gear has a coated friction surface on the inside -arrow 1- and is conical.
-A- The inner ring for 2nd gear has no friction surface on the inside -arrow 2- and is cylindrical.
  A35-10127
Checking 1st gear inner ring for wear
–  Check outer contact surface -arrow- for scoring or visible traces of wear and renew if necessary.
–  Press inner ring onto chamfer on selector gear and measure gap -a- using a feeler gauge.
  A35-0095
Gap -a-Wear limit
Inner ring for 1st gear0.6 mm

   
Checking 1st and 2nd gear intermediate ring for wear
–  Check inner friction surface of synchro-ring for grooves or scoring and renew if necessary.
–  Fit inner ring, intermediate ring and synchro-ring on selector gear and rotate rings until they are »seated«.
  Note
To achieve proper seating, rotate synchro-rings approx. one turn while pressing down rings simultaneously.
–  Then measure gap -a- using a feeler gauge.
  A35-0087
Gap -a-Wear limit
1st and 2nd gear0.7 mm

  Note
Renew inner ring, intermediate ring and synchro-ring for the corresponding gear together.
   
Assembling 1st and 2nd gear locking collar/synchro-hub
–  Fit locking collar -1- onto synchro-hub -2- so that wide teeth of locking collar -arrow A- and synchro-hub -arrow B- coincide.
l  Installation position of synchro-hub: high inside collar -arrow C- faces 2nd speed selector gear.
–  Then fit thrust blocks -3- in synchro-hub and press them into recesses -arrows D- in locking collar.
  A35-10128

Exploded view - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft > < Output shaft