Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust piece -VW 431-

t	Thrust piece -VW 432-

t	Press tool -VW 454-

t	Press tool -30–505-

t	Thrust plate -40-105-

t	Tube -2040-

t	-1-Internal puller -Kukko 21/5-

t	-2-Puller -Kukko 18/1-

t	-3-Splitter -Kukko 17/1-

t	-3-Splitter -Kukko 17/2-

t	-4-Counter-support -Kukko 22/2-

Lubricate all bearings on input shaft with gear oil before installing.

1 -

Circlip

q	For grooved ball bearing on input shaft → Item

q	Removing and installing → Chapter

2 -

Shim

q	Outside diameter = 78.6 mm

q	Can only be fitted on modified gearbox housing (from gearbox manufacturing date 10 04 6 to 20 01 8) → Chapter

q	Select correct components from → Electronic parts catalogue

3 -	Gearbox housing

q	From gearbox manufacturing date 10 04 6 to 20 01 8: modified in area of seat for grooved ball bearing → Item to match shims → Item and → Item → Chapter

q	From gearbox manufacturing date 21 01 8 onwards, grooved ball bearing and bearing seat have flattened sides → Chapter

q	Select correct components from → Electronic parts catalogue

4 -

Shim

q	Outside diameter = 85 mm

q	Can only be fitted on modified gearbox housing (from gearbox manufacturing date 10 04 6 to 20 01 8) → Chapter

q	Select correct components from → Electronic parts catalogue

5 -

Circlip

q	When grooved ball bearing → Item or input shaft → Item are renewed: determine thickness of required circlip → Fig.

6 -	Grooved ball bearing

q	Always renew

q	Pulling off → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

q	From gearbox manufacturing date 21 01 8 onwards, grooved ball bearing and bearing seat have flattened sides → Chapter

7 -	5th gear wheel

q	Pressing off → Fig.

q	Installation position: Circular slot -arrow- faces towards grooved ball bearing → Item

q	Pressing on → Fig.

8 -	Input shaft

q	With 3rd/4th and 6th gear wheels

9 -	Roller bearing

q	With circlip

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Installation position: Circlip in bearing faces towards input shaft

10 -	Clutch housing

Pulling off grooved ball bearing –  First remove circlip from input shaft. –  Before setting up puller, position thrust piece -VW 431- and thrust plate -40-105- on input shaft. –  Apply splitter -B- at circular slot for circlip in bearing. A -  Puller, e.g. -Kukko 18/1- B -  Splitter 12...75 mm, e.g. -Kukko 17/1-

Pressing off 5th gear wheel A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing on 5th gear wheel Slot -arrow- on gear wheel must face upwards.

Installation position of grooved ball bearing Slot for circlip faces upwards -arrow A- and shoulder -arrow B- must face towards 5th gear wheel.

Pressing on grooved ball bearing Grooved ball bearing with rubber ring -arrow- Shoulder -A- faces towards press tool -VW 412-. –  Determine thickness of circlip for grooved ball bearing on input shaft (⇒ next illustration) and fit circlip.

Determining thickness of circlip for grooved ball bearing on input shaft –  Install a 1.86 mm thick circlip -A- in slot on input shaft and press circlip upwards. –  Measure gap between grooved ball bearing -B- and fitted circlip -A- using feeler gauge -C-. –  Remove circlip fitted for measurement. –  Select circlip from table.   Note Select circlips from → Electronic parts catalogue. The following circlips are available:

Measured value (mm)	Circlip thickness (mm)	Axial clearance (mm)
0.01 … 0.05	1.86	0.01 … 0.05
0.05 … 0.07	1.89	0.01 … 0.05
0.07 … 0.10	1.92	0.01 … 0.05
0.10 … 0.13	1.95	0.01 … 0.05
0.13 … 0.16	1.98	0.01 … 0.05

Pulling roller bearing out of clutch housing –  When pulling out, compress circlip -arrow- for roller bearing using pliers -C-. A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 30 ... 37 mm, e.g. -Kukko 21/5-

Pressing roller bearing into clutch housing –  When pressing in, compress circlip -arrow- for roller bearing using pliers -A-. –  Remove the pliers before the roller bearing is in its final position. The circlip must engage in the groove in the clutch housing.