Audi Workshop Service and Repair Manuals

Exploded view - output shaft

t	Refer to → Electronics parts catalogue and technical data when installing new gear wheels or a new output 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 output 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 -	Roller bearing

q	With circlip

q	Removing and installing → Chapter

q	Installation position: the circlip in the bearing faces the output shaft

2 -	Output shaft

q	With inner race for roller bearing (depending on version)

q	Inner race cannot be removed from output shaft

q	Check bearing seat / bearing inner race for scoring or other damage

q	If you detect scoring or other damage to the bearing seat / inner race, renew both output shaft and roller bearing

3 -	4th gear wheel

q	Installation position: Collar faces 3rd gear → Fig.

q	Removing and installing → Chapter

4 -

Circlip

5 -

Circlip

6 -	3rd gear wheel

q	Installation position: Collar faces 4th gear → Fig.

q	Removing and installing → Chapter

7 -

Circlip

8 -	Needle bearing

q	For 2nd gear

9 -	2nd speed selector gear

10 -	Inner ring for 2nd gear

q	Removing and installing → Chapter

q	Checking for wear →

11 -	Outer ring for 2nd gear

q	Removing and installing → Chapter

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

12 -	2nd gear synchro-ring

q	Removing and installing → Chapter

q	Checking for wear →

13 -	Locking collar with synchronising hub for 1st and 2nd gear

q	Removing and installing → Chapter

q	Dismantling and assembling → Fig.

14 -

Circlip

15 -	1st gear synchro-ring

q	Removing and installing → Chapter

q	Checking for wear →

16 -	Outer ring for 1st gear

q	Removing and installing → Chapter

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

17 -	Inner ring for 1st gear

q	Removing and installing → Chapter

q	Checking for wear →

q	Check lugs for scoring

18 -	Needle bearing

q	For 1st gear

19 -	1st speed selector gear

q	Removing and installing → Chapter

20 -

Spring

q	Installation position → Fig.

21 -	Locking collar for 1st and 2nd gear

q	Dismantling and assembling → Fig.

22 -	Synchronising hub for 1st and 2nd gear

q	Dismantling and assembling → Fig.

23 -	Locking pieces

q

3x

24 -

Spring

q	Installation position → Fig.

Installation position of 3rd and 4th gear wheel Installation position of 4th gear wheel -A-: l  Collar -arrow 1- faces 3rd gear wheel -B-. Installation position of 3rd gear wheel -B-: l  Collar -arrow 2- faces 4th gear wheel -A-.

Checking 1st and 2nd gear inner ring 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 against 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 synchronising hub –  Take off springs -1- before dismantling. 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  To assemble, slide locking collar over synchronising hub. Installation position: l  After assembly, the groove on the top -arrow A- and the higher shoulder -arrow B- on the synchronising hub will face towards the external splines on the locking collar -arrow C-. l  The deeper recesses -arrow D- for the locking pieces in the synchronising hub must align with the recesses -arrow E- in the locking collar.

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