Audi Workshop Service and Repair Manuals

Exploded view - dismantling and assembling output shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust pad -VW 512-

t	Puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	Adapter -V.A.G 1582/5-

t	Thrust plate -VW 402-

t	Thrust piece -32 - 111-

t	Press tool -VW 408 A-

t	Press tool -VW 409-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Thrust ring -VW 429-

t	Tube -VW 415 A-

t	Thrust plate -VW 447 H-

t	Press tool -VW 454-

t	Installing sleeve -VW 455-

t	Drift sleeve -41-501-

t  Internal puller -1 - - Kukko 21/6- t  Counter-support -2 - -Kukko 22/2- t  Splitter -3- -Kukko 17/2-

t	The output shaft is dismantled as follows:- Position splitter under 2nd speed selector gear ( → Item) and press off as described in → Fig.. Remove circlip → Item. Then press off locking collar and synchro-hub for 1st and 2nd gear as shown in → Fig..

t	Refer to → Electronic parts catalogue and technical data → Chapter when installing new gears or a new output shaft.

t	Always renew both tapered roller bearings together.

1 -

Nut

q	25 Nm + 90°

q	4 nuts for bearing mounting

q	Always renew

2 -	Clutch housing

3 -

Shim

q	For output shaft

q	Table of adjustments → Chapter

4 -	Small tapered roller bearing outer race

q	Removing → Fig.

q	Pressing in → Fig.

5 -	Small tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

6 -	Output shaft

q	Is paired with final drive gear, only renew as a set

q	Adjusting → Chapter

7 -	Large tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

8 -

O-ring

q	Place O-rings (4x) on bolts for bearing mounting

9 -	Bearing mounting

q	With large tapered roller bearing outer race and bolts

q	Only renew outer race together with large tapered roller bearing and bearing mounting

10 -	Thrust washer

q	Shoulder on thrust washer faces towards tapered roller bearing

11 -	1st speed selector gear

12 -	Needle bearing

q	For 1st gear

13 -	Synchro-ring

q	(Inner ring for 1st gear)

q	Installation position → Fig.

q	Checking for wear → Fig.

q	Check lugs for scoring

14 -	Outer 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

15 -	1st gear synchro-ring

q	Installation position → Fig.

q	Checking for wear → Fig.

16 -	Locking collar with synchro-hub for 1st and 2nd gear

q	Press off together with bearing mounting → Item after removing circlip → Fig.

q	Dismantling → Fig.

q	Assembling locking collar/synchro-hub → Fig., → Fig. and → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

17 -

Circlip

18 -	2nd gear synchro-ring

q	Checking for wear → Fig.

q	Assemble so that the recesses engage on the locking pieces on the locking collar → Item

19 -	Outer ring for 2nd gear

q	Insert in synchro-ring → Item

q	Installation position → Fig.

q	Renew if scored or if there are visible traces of wear

20 -	Synchro-ring

q	(Inner ring for 2nd gear)

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

21 -	2nd speed selector gear

q	Installation position → Fig.

22 -	Needle bearing

q	For 2nd gear

23 -	Thrust washer

24 -	Sleeve for 3rd gear needle bearing

q	Pressing off with 2nd speed selector gear → Fig.

q	Pressing on → Fig.

25 -	Needle bearing

q	For 3rd gear

26 -	3rd speed selector gear

27 -	3rd gear synchro-ring

q	Checking for wear → Fig.

28 -	Locking collar with synchro-hub for 3rd and 4th gear

q	Pressing off with 2nd speed selector gear → Item and 3rd speed selector gear → Item → Fig.

q	Dismantling → Fig.

q	Assembling locking collar/synchro-hub → Fig., → Fig. and → Fig.

q	Installation position: Locking collar/synchro-hub → Fig.

q	Pressing on → Fig.

29 -

Sleeve

q	For needle bearing

q	Pressing off with locking collar and synchro-hub for 3rd and 4th gear → Item → Fig.

q	Pressing on → Fig.

30 -	Needle bearing

q	For 4th gear

31 -	4th gear synchro-ring

q	Checking for wear → Fig.

32 -	4th speed selector gear

33 -	Thrust washer

34 -	Needle bearing

q	For output shaft

q	Removing and installing → Fig.

35 -	Gearbox housing

36 -

Sleeve

q	For needle bearing/output shaft

q	Pressing off → Fig.

q	Pressing on → Fig.

37 -	5th gear wheel

q	Pulling off individually → Chapter

q	Pulling off together with gearbox housing → Chapter

38 -	Dished spring

q	Installation position → Fig.

39 -

Bolt

q	Tightening torque → Item

q	Always renew

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

q	Removing and installing → Chapter

Pulling out small tapered roller bearing outer race A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2-

Pressing in small tapered roller bearing outer race

Pulling off small tapered roller bearing inner race A -  Soft jaws/vice –  Fit adapter and apply tension to it behind the bearing rollers, then turn bearing and re-tension adapter.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub/locking collar; 2nd, 3rd and 4th speed selector gears with needle bearing sleeve for output shaft A -  Splitter 22...115 mm, e.g. -Kukko 17/2- B -  Hexagon bolt (M10 x 20), 17 mm   Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing mounting –  First remove circlip -arrow-.

Pulling off large tapered roller bearing inner race A - Soft jaws –  Before applying puller insert a M10 x 20 hexagon bolt in output shaft hole.

Pressing on large tapered roller bearing inner race -A- Thrust washer –  Fit thrust washer before pressing on inner race. Shoulder faces towards inner race.

Installation position of inner ring, outer ring and synchro-ring for 1st gear –  Place inner ring -A- on 1st speed selector gear. The angled tabs -arrow 1- point towards the outer ring -B-. –  Fit outer ring -B-. The tabs -arrow 2- lock in the recesses -arrow 3- of the selector gear. –  Fit synchro-ring -C-. The recesses -arrow 4- locate on the tabs -arrow 1- of the inner ring -A-.   Note If components are not being renewed, make sure they are re-installed on the same gear.

Checking inner ring for 1st and 2nd gear for wear –  Press inner ring onto tapered seat on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation depth	Wear limit
1st and 2nd gear	0.75…1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-ring for wear –  Press synchro-ring, outer ring and inner ring onto tapered seat on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation depth	Wear limit
1st and 2nd gear	1.2…1.8 mm	0.5 mm

Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub 1 -  Spring Select correct spring from → Electronic parts catalogue. Assembling version used together with hollow locking pieces (with internal recess) → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece Select locking pieces from → Electronic parts catalogue. Shoulders on synchro-hub are of equal width on both sides. The shoulder on one side is chamfered -arrow B-. When assembled, the chamfer on the shoulder of the synchro-hub and the external teeth on the locking collar -arrow A- face in the same direction. The recesses for the locking pieces on synchro-hub and locking collar -arrow C- must align.

Assembling locking collar/synchro-hub for 1st and 2nd gear (version with hollow locking pieces) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Assembling locking collar/synchro-hub for 1st and 2nd gear (version with solid locking pieces: no internal recess) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled ends of spring must be in front of locking pieces -arrows-.

Installation position of 1st and 2nd gear locking collar/synchro-hub Splines on locking collar -arrow- point to splines for 3rd/4th gear synchro-hub -A-.

Pressing on 1st and 2nd gear locking collar/synchro-hub Turn synchro-ring so that grooves align with locking pieces.

Installation position of outer ring for 2nd gear The lugs -arrows- face towards 1st gear -A-.

Installation position of synchro-ring (inner ring for 2nd gear) -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-.

Installation position of 2nd speed selector gear The higher shoulder -A- faces towards 1st gear -B-. The recesses in the shoulder -arrows- engage on the lugs on the outer ring → Fig..

Pressing on sleeve for 3rd gear needle bearing

Checking 3rd and 4th gear synchro-ring for wear –  Press synchro-ring onto tapered seat on selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation depth	Wear limit
1st gear 3rd gear 4th gear	1.0…1.7 mm 1.0…1.7 mm 1.0…1.7 mm	0.5 mm

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring Select correct spring from → Electronic parts catalogue. Assembling version used together with hollow locking pieces (with internal recess) → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Locking piece Select locking pieces from → Electronic parts catalogue. 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Recesses for locking pieces in synchro-hub and locking collar must align.

Assembling locking collar/synchro-hub for 3rd and 4th gear (version with hollow locking pieces) Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Assembling locking collar/synchro-hub for 3rd and 4th gear (version with solid locking pieces: no internal recess) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled ends of spring must be in front of locking pieces -arrows-.

Installation position of 3rd and 4th gear locking collar/synchro-hub Chamfer -arrow- faces towards 4th gear.

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

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for needle bearing/output shaft