Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft - assembly sequence

Special tools and workshop equipment required

t	Drift sleeve -VW 244 B-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust piece -VW 434-

t	Thrust piece -VW 454-

t	Installing sleeve -VW 455-

t	Tube -VW 519-

t	Drift sleeve -40 - 21-

t	Support bridge -2011-

t	Wheel bearing tube -3345-

t  -3-Splitter -Kukko 17/2-

t  Inductive heater -VAS 6414- t  Depth gauge Dismantling input shaft l  Input shaft has been detached from output shaft and bearing mounting → Chapter. l  Bolt in input shaft has been loosened and removed → Anchor.

–  Press off 3rd speed, 4th speed and 6th speed selector gears together with synchronising hub for 3rd/4th gear and needle bearing inner races. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Support splitter -A- against 6th speed selector gear so that 5th/6th gear locking collar is not pulled off at the same time. –  Detach circlip for 5th /6th gear synchronising hub from input shaft.   Note Mark this circlip so that it is not interchanged with the circlip below the 5th /6th gear synchronising hub.

–  Press off locking collar with 5th/6th gear synchronising hub and 5th speed selector gear.

–  Open out needle bearing -2- for 5th gear and guide it carefully over circlip -1- and teeth -3- for 5th/6th gear synchronising hub.   Note t  The circlip -1- below teeth -3- for the 5th/6th gear synchronising hub should only be removed from the input shaft if the roller bearing is being renewed (next step). t  Always renew the circlip if it has been removed. –  Remove circlip -1-.

–  Press roller bearing off input shaft. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note t  The roller bearing will be damaged when it is pressed off and must therefore always be renewed. t  To press off the roller bearing, you can also break open the cage of the bearing using a screwdriver or similar and then apply the splitter to the inner race. –  Clean thread for bolt in input shaft to remove any remaining locking fluid. Assembling input shaft   Note t  Lubricate all needle bearings and synchro-rings with gear oil before fitting. t  Heat needle bearing inner races to 130 °C (max.) before pressing on (wear protective gloves). t  Heat synchronising hubs to 100 °C (max.) before pressing on (wear protective gloves). t  Always press on roller bearing, needle bearing inner races and synchronising hubs as far as stop to make sure the axial clearance of the selector gears meets the specification.

Inserting spring in selector gear The bent end of the spring -arrow- must be hooked into the hole in the selector gear.

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.   Note If components are not being renewed, make sure they are re-installed on the same gear.

–  Press roller bearing onto input shaft as far as stop.

–  Carefully open out new circlip -1- and guide it over teeth for 5th/6th gear synchronising hub -3-. l  It should not be possible to turn the circlip in the annular groove on the input shaft by hand –  Open out needle bearing -2- for 5th speed selector gear and guide it carefully over circlip -1-; do not seat needle bearing on shoulder -arrow- of input shaft.

–  Install 5th speed selector gear -B-. l  When rotated, selector gear -B- must not come into contact with circlip -A-. l  There must be a uniform clearance -x- between selector gear and circlip all round. –  Fit 5th gear synchro-ring.

Installation position of 5th/6th gear synchronising hub and locking collar l  The shorter teeth -arrow A- above the annular groove -arrow B- of synchronising hub -1- must face towards 6th speed selector gear. l  The groove -arrow C- on the face of locking collar -2- must face towards 6th gear. –  Slide locking collar -2- over synchronising hub -1-. Note the following when performing the following steps: –  Fit input shaft in drilling of support bridge -2011-. –  Position drift sleeves on centre of heated components (synchronising hub and needle bearing inner races). –  First press on components just briefly, then stop exerting pressure and check whether drift sleeves are still positioned properly and press on as far as stop.

Pressing on 5th and 6th gear synchronising hub with locking collar

Determining thickness of circlip for synchronising hub for 5th and 6th gear l  Synchronising hub is pressed on as far as stop. –  Determine the thickest circlip that will just fit and install it. For part number refer to → Electronic parts catalogue. The following circlips are available:

Circlip thickness (mm)
2.44	2.47	2.50

–  Install 6th speed selector gear with needle bearing and synchro-ring.

–  Fit thrust washer -A-. –  Press on needle bearing inner race -B- for 3rd speed selector gear. –  Install 3rd speed selector gear with needle bearing and synchro-ring.

Installation position of 3rd/4th gear synchronising hub and locking collar l  The lower inside collar -arrow A- of the synchronising hub faces 4th gear. l  The groove -arrow B- on the face of locking collar -2- must face towards 4th gear. –  Slide locking collar -2- over synchronising hub -1-.

Pressing on 3rd and 4th gear synchronising hub with locking collar

Pressing on needle bearing inner race -A- for 4th speed selector gear –  Install 4th speed selector gear together with needle bearing and synchro-ring.

–  Fit thrust washer -A-. –  Press on inner race -B- for roller bearing. –  Then check all selector gears for freedom of movement and axial play. l  The axial play of the selector gears must be at least 0.15 mm.   Note Tighten bolt securing input shaft to specified torque → Anchor.