Audi Workshop Service and Repair Manuals

Assembly sequence - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft

Special tools and workshop equipment required

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Thrust plate -VW 447 H-

t	Thrust plate -40 - 105-

t	Tube -3296-

t	Workshop press -V.A.G 1290A-

t  Inductive heater -VAS 6414-

t  Gearbox support -T40206-

t  Separating tool -T40213-

t  -1-Two-arm puller -Kukko 20/10- t  -2-Hook, 200 mm Removing selector fork cluster, input shaft, 1st, 2nd and reverse gears from output shaft

–  Attach plate -T40213/1- to gearbox support -T40206- with bolts -arrows-. –  Fit adapters -T40213/6- and -T40213/7- in plate -T40213/1-.   Note Secure adapters with knurled screws -T40213/3- after inserting input and output shafts.

–  Insert input shaft -1- together with output shaft -2- and selector fork cluster -3- in adapters -T40213/6- and -T40213/7-. –  Remove bolts -arrows- and detach selector fork cluster from bearing mounting -4-.

–  Detach thrust washer -A-, reverse gear synchronising hub -B- and reverse selector gear -C-.

–  Pull off 1st speed selector gear -E- and needle bearing inner race for reverse gear -C- and thrust washer -D-. A -  Two-arm puller, e.g. -Kukko 20/10- B -  Hook, 200 mm   Caution Risk of damage to dog teeth on 1st speed selector gear -E- Hooks of the two-arm puller must not come into contact with dog teeth of 1st speed selector gear during removal.

–  Pull off 2nd speed selector gear -E- with needle bearing inner race for 1st gear -C- and synchronising hub/locking collar for 1st/2nd gear -D-. A -  Two-arm puller, e.g. -Kukko 20/10- B -  Hook, 200 mm

–  Detach needle bearing -1-. –  Detach bearing mounting -2- from input shaft -4- and output shaft -3-.   Note t  Dismantling and assembling output shaft → Chapter t  Dismantling and assembling input shaft → Chapter Installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft

–  Place plate -T40213/1- with adapters -T40213/6- and -T40213/7- on work table of workshop press -V.A.G 1290A-. –  Insert output shaft -1- and input shaft -2- in adapters -T40213/6- and -T40213/7-. –  Fit bearing mounting -3- in correct position over the two shafts, with projections -arrows- facing upwards.

Installation position of synchro-rings for 1st, 2nd and reverse gear   Note If components are not being renewed, make sure they are re-installed on the same gear. –  Fit inner ring -2- onto selector gear -1-. –  Fit intermediate ring -3-. Lug -B- must be inserted into recess -A-. –  Fit synchro-ring -4-. Guide lugs -C- through recess -arrow-. –  Install 2nd speed selector gear with needle bearing and synchro-rings.

Pressing on locking collar with synchronising hub for 1st/2nd gear   Note t  Heat synchronising hub to approx. 100°C. t  Note installation position of locking collar/synchronising hub → Fig.. t  When pressing on the synchronising hub, lift the 2nd speed selector gear slightly so that the lugs on the synchro-ring engage in the slots in the hub.

Heat needle bearing inner race -A- for 1st speed selector gear to max. 100° C and press on.

–  Install 1st speed selector gear -A- with synchro-rings and needle bearing on output shaft. –  Fit thrust washer -B- and pre-heated inner race -C- for needle bearing for reverse selector gear.

–  Fit reverse selector gear -C- with needle bearing and locking collar for reverse gear. –  Fit reverse gear synchronising hub -B- with synchro-rings and thrust washer -A-.

–  Secure plate -T40213/1- to gearbox support -T40206-. –  Clean threads of bolts -arrows- with a wire brush. Then coat bolts with locking fluid -AMV 185 101 A1-. –  Secure selector fork cluster -3- to bearing mounting -4- with bolts -arrows-. –  Take input shaft -1- with output shaft -2- and selector fork cluster out of plate -T40213/1-.