Audi Workshop Service and Repair Manuals

Exploded view - dismantling and assembling input shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Thrust plate -VW 447 H-

t	Press tool -VW 412-

t	Tube -VW 422-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Tube -VW 421-

t	Press tool -VW 454-

t	Thrust plate -VW 447 i-

t	Thrust pad -VW 510-

t	Drift sleeve -41-501-

t	-3-Splitter -Kukko 17/1-

t	When fitting new gear wheels or input shaft, refer to technical data → Chapter and → Electronic parts catalogue.

t	The input shaft must be re-adjusted if the position of tapered roller bearings is affected when renewing parts. Refer to table of adjustments → Chapter.

1 -	Clutch housing

2 -	Tapered roller bearing outer race

q	Pressing out → Fig.

q	Pressing in → Fig.

3 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

4 -	Input shaft

q	Adjusting → Chapter

5 -	3rd gear wheel

q	Installation position: Collar faces 4th gear

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -

Circlip

q	Always renew

7 -	4th gear wheel

q	Pressing off with tapered roller bearing outer race and sleeve → Fig.

q	Pressing on → Fig.

q	Shoulder faces towards 3rd gear

8 -	Tapered roller bearing inner race

q	Pressing off with 4th gear wheel and sleeve → Fig.

q	Pressing on → Fig.

9 -	Thrust washer

10 -	Tapered roller bearing outer race

q	Pressing out → Fig.

q	Pressing in → Fig.

11 -

Shim

q	Determining thickness → Chapter

12 -	Gearbox housing

13 -

Sleeve

q	For needle bearing

q	Press off with 4th gear wheel and tapered roller bearing inner race → Fig.

q	Pressing on → Fig.

q	Fit thrust washer → Item before installing

14 -	Needle bearing

15 -	5th speed selector gear

q	Pull off together with 5th gear synchro-hub → Chapter

16 -	5th gear synchro-ring

q	With cast locking pieces → Fig.

q	Checking for wear → Fig.

17 -

Spring

q	Offset version → Fig.

q	Installation position → Fig.

18 -	Locking pieces (3x)

q	Installation position → Fig.

19 -	5th gear synchro-hub

q	Pulling off individually → Chapter

q	Pulling off together with gearbox housing → Chapter

q	Dismantling and assembling → Fig.

20 -	5th gear locking collar

q	Removing and installing → Chapter

21 -	Dished spring

q	Installation position → Fig.

22 -

Bolt

q	Tightening torque → Item

q	Always renew

q	Fitted piece on bolt head holds dished spring in position → Fig.

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race A -  Splitter-Kukko 17/1-

Pressing on tapered roller bearing inner race

Pressing off 4th gear wheel with tapered roller bearing and sleeve

Pressing off 3rd gear wheel

Pressing on 3rd gear wheel

Pressing on 4th gear wheel Shoulder faces towards 3rd gear.

Pressing on tapered roller bearing inner race

Pressing on sleeve for needle bearing

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race –  Install with shim after adjusting input shaft.

5th gear synchromesh 1 -  Springs for locking pieces 2 -  Locking collar with 3 recesses -arrows A- for locking pieces -4- 3 -  Synchro-hub 4 -  Locking pieces - Installation position: The thin extension -arrow B- faces the pointed teeth of the locking collar -2-

Assembling 5th gear locking collar/synchro-hub –  Slide locking collar over synchro-hub. Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. The recesses for the locking pieces in locking collar and synchro-hub must be aligned ( → Fig.). –  Fit locking pieces (installation position: → Fig. ). –  Insert springs offset by 120° underneath lug -C-. Angled ends of spring must be in front of locking pieces -arrows-.

Installing offset springs -A- This type of spring is fitted on both sides. –  The springs are only used together with hollow locking pieces (with internal recess). –  Fit locking pieces (installation position: → Fig. ).

Installation position of springs: –  Insert springs offset by 120°. –  Angled end -A- of spring must locate in hollow locking piece. Spring must be fitted under lug -B- of locking pieces. The offset end must always point away from synchro-hub (in direction of -arrow-).