Audi Workshop Service and Repair Manuals

Exploded view - input shaft

t	Refer to → Electronics parts catalogue and technical data when installing new gear wheels or a new input shaft.

t	Pressing input and output shaft out of bearing mounting and grooved ball bearings → Chapter

t	Lubricate all bearings, selector gears and synchro-rings on input shaft with gear oil before installing.

t	Do not interchange synchro-rings. When re-using synchro-rings, always fit on the same selector gear.

1 -	Input shaft

2 -	Needle bearing

q	For 3rd gear

3 -	3rd speed selector gear

4 -	3rd gear synchro-ring

q	Checking for wear → Fig.

5 -	Locking collar with synchronising hub for 3rd and 4th gear

q	Removing and installing → Chapter

q	Dismantling and assembling →

q	Installation position: Locking collar/synchronising hub → Fig.

6 -	4th gear synchro-ring

q	Checking for wear → Fig.

q	Checking for wear → Fig.

7 -

Sleeve

q	For 4th gear needle bearing

q	Removing and installing → Chapter

q	Renew together with → Item

8 -	Needle bearing

q	For 4th gear

q	Removing and installing → Chapter

q	Renew together with → Item

9 -	4th speed selector gear

10 -	Thrust washer

11 -	Inner race for roller bearing

q	Removing and installing → Chapter

12 -

Circlip

q

Renew

q	Determining thickness → Anchor

13 -	Roller bearing

q	With circlip

q	Removing and installing → Chapter

14 -

Spring

q	Installation position: angled end of spring must locate in one of the locking pieces.

15 -	Locking collar for 3rd and 4th gear

q	Dismantling and assembling →

q	Installation position: Locking collar/synchronising hub → Fig.

16 -	Synchronising hub for 3rd and 4th gear

17 -	Locking pieces

q

3x

18 -

Spring

q	Installation position: angled end of spring must locate in one of the locking pieces.

Checking 3rd and 4th gear synchro-ring for wear –  Press synchro-ring onto taper of selector gear and measure gap dimension -a- with feeler gauge.

Gap -a-	Installation depth	Wear limit
3rd and 4th gear	1.1 ... 1.7 mm	0.5 mm

Installation position of 3rd and 4th gear locking collar/synchronising hub The groove on the top -arrow- and the flatter contact shoulder in the inside face towards 4th gear.

Dismantling and assembling 3rd and 4th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. The deeper recesses -arrow A- for the locking pieces in the synchronising hub must align with the recesses -arrow B- in the locking collar.

–  Fit locking pieces in the smaller slots -arrows- and install springs so they are offset 120°. l  Angled end of spring must locate in one of the locking pieces.