Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st - 4th gear

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 408A-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Thrust piece -VW 431-

t	Press tool -VW 433-

t	Press tool -VW 454-

t	Thrust pad -VW 512-

t	Tube -VW 516-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Press tool -40-21-

t	Thrust piece -2050-

t	Engine and gearbox support supplement -VW 540/1 B-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/7-

t  -1-Internal puller -Kukko 21/7- t  -1-Internal puller -Kukko 21/8- t  -2-Puller -Kukko 18/2- t  -3-Splitter -Kukko 17/2- t  -4-Counter-support -Kukko 22/2-

t	Carry out output shaft adjustment → Chapter if the output shaft or tapered roller bearings have been renewed .

t	Always renew both tapered roller bearings together.

1 -	Clutch housing

2 -	Oil deflector plate

3 -	Dished washer

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

5 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -	Output shaft

q	For 1st to 4th gear

q	Adjusting → Chapter

7 -	Needle bearing

q	For 2nd gear

8 -	2nd speed selector gear

9 -	Synchro-ring

q	(Inner ring for 2nd gear)

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

10 -	Outer ring for 2nd gear

q	Fit on synchro-ring → Item

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

q	Installation position → Fig.

11 -	2nd gear synchro-ring

q	Checking for wear → Fig.

q	Installation position → Fig.

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

q	Press off together with 2nd speed selector gear after removing circlip → Item → Fig.

q	Dismantling → Fig.

q	Assembling locking collar/synchro-hub → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

13 -

Circlip

14 -	1st gear synchro-ring

q	Checking for wear → Fig.

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

15 -	Outer ring for 1st gear

q	Insert in synchro-ring → Item; installation position → Fig.

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

16 -	Synchro-ring

q	(Inner ring for 1st gear)

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

17 -	Needle bearing

q	For 1st gear

18 -	1st speed selector gear

q	Installation position → Fig.

19 -	Thrust washers

q	For 1st and 4th gear

q

2x

q	Insert lug on thrust washer in hole on output shaft

20 -	Securing clip

q	Holds thrust washers → Item in position on output shaft

21 -	Needle bearing

q	For 4th gear

22 -	4th speed selector gear

23 -	4th gear synchro-ring

q	Checking for wear → Fig.

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

q	Pull off together with 4th speed selector gear after removing circlip → Item → Fig.

q	Dismantling → Fig.

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

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

q	Pressing on → Fig.

25 -

Circlip

26 -	3rd gear synchro-ring

q	Checking for wear → Fig.

27 -	Outer ring for 3rd gear

q	Insert in synchro-ring → Item; installation position → Fig.

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

28 -	Synchro-ring

q	(Inner ring for 3rd gear)

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

29 -	Needle bearing

q	For 3rd gear

30 -	3rd speed selector gear

q	Installation position → Fig.

31 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

32 -

Circlip

q	When tapered roller bearing → Item or output shaft → Item are renewed: determine thickness of required circlip → Fig.

33 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

34 -

Shim

q	Determining thickness → Chapter

35 -	Gearbox housing

Pulling dished washer -A- out of output shaft

Pressing dished washer into output shaft Dimension „a“ = 2 mm

Pulling out tapered roller bearing outer race A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 56 ... 70 mm, e.g. -Kukko 21/8-

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with drift sleeve -40-20- directly below bearing mounting.

Pulling off tapered roller bearing inner race –  First remove circlip. –  Before applying puller, fit press tool -VW 431- in output shaft and place thrust plate -40-105- on it.

Pulling off 3rd and 4th gear synchro-hub/locking collar with 4th speed selector gear –  First remove circlip. A -  Puller, e.g. -Kukko 18/2- B -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing off 1st and 2nd gear locking collar and synchro-hub After removing the circlip, press off 2nd speed selector gear and locking collar/synchro-hub together.

Pressing off tapered roller bearing inner race A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing on tapered roller bearing inner race

Checking inner ring for 1st, 2nd and 3rd 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, 2nd and 3rd gear	0.75…1.25 mm	0.3 mm

Checking 1st, 2nd and 3rd gear synchro-rings 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, 2nd and 3rd gear	1.2…1.8 mm	0.5 mm

Installation position of outer ring, inner ring and synchro-ring of 2nd gear –  Place inner ring -A- on 2nd speed selector gear. The angled lugs -arrows 1- point towards outer ring -B-. –  Fit outer ring -B-. The lugs -arrows 2- lock in the slots -arrows 3- on the selector gear. –  Fit synchro-ring -C-. The slots -arrows 4- locate on the lugs -arrows 1- of inner ring -A-.

Dismantling and assembling 1st/2nd gear and 3rd/4th gear locking collar/synchro-hub 1 -  Spring 2 -  Locking piece 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 1st/2nd gear and 3rd/4th gear locking collar/synchro-hub 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.

Installation position of 1st and 2nd gear locking collar/synchro-hub Identification groove -arrow 1- and narrow shoulder -arrow 2- on synchro-hub point towards 1st gear.

Pressing on 1st and 2nd gear locking collar/synchro-hub –  Fit circlip.

Installation position of 1st or 3rd gear outer ring Lugs -arrows- face towards synchro-hub/locking collar -A-.

Installation position of synchro-ring -A- (inner ring for 1st or 3rd gear) Lugs -arrows 1- locate in the recesses -arrows 2- in the synchro-ring -B-.

Installation position of 1st and 3rd speed selector gear The higher shoulder -A- faces towards 2nd or 4th gear -B-. The recesses in the shoulder -arrows- engage on the lugs on the outer ring → Fig..

Installation position of 3rd and 4th gear locking collar/synchro-hub The wider shoulder on the synchro-hub -arrow- faces towards 3rd gear.

Pressing on 3rd and 4th gear synchro-hub with locking collar –  Fit circlip.

Checking 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
4th gear	1.0…1.7 mm	0.5 mm

Pressing on tapered roller bearing inner race –  Determine thickness of required circlip → Fig. and install circlip.

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it.   Note Select circlips from → Electronic parts catalogue. The following circlips are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Pulling tapered roller bearing outer race out of gearbox housing A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 46 ... 58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Fit shim below outer race. –  Support gearbox housing with thrust piece -2050- directly below bearing mounting.