Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 5th, 6th and reverse 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 415A-

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Press tool -VW 433-

t	Press tool -VW 454-

t	Support rails -VW 457-

t	Support plate -VW 801-

t	Thrust piece -VW 431-

t	Installing sleeve -VW 455-

t	Thrust pad -VW 510-

t	Tube -VW 516-

t	Tube -VW 519-

t	Thrust plate -30-11-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Thrust piece -2050-

t	Tube -3296-

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

t	Adapter -V.A.G 1582/4-

t  Adapter -V.A.G 1582/7-

t  -1-Internal puller -Kukko 21/7- 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 -

Shim

q	Always 0.65 mm thick

3 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

5 -	Output shaft

q	For 5th, 6th and reverse gears

q	Adjusting → Chapter

6 -	Reverse gear synchro-hub

q	Pressing off → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

7 -

Circlip

8 -	Reverse gear locking collar

q	With synchro-ring

9 -	Needle bearing

q	For reverse selector gear

10 -	Reverse selector gear

11 -

Sleeve

q	Press off with reverse selector gear → Fig.

q	Installation position: Wide shoulder of sleeve faces towards reverse selector gear

q	Pressing on → Fig.

12 -

Circlip

13 -	Needle bearing

q	For 6th gear

14 -	6th speed selector gear

15 -	6th gear synchro-ring

q	Checking for wear → Fig.

16 -	Locking collar with synchro-hub for 5th and 6th gear

q	Press off together with 6th speed selector gear after removing circlip → Item → Fig.

q	Dismantling → Fig.

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

q	Pressing on → Fig.

17 -

Circlip

18 -	Needle bearing

q	For 5th gear

19 -	5th gear synchro-ring

q	Checking for wear → Fig.

20 -	5th speed selector gear

21 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

22 -

Circlip

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

23 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

24 -

Shim

q	Determining thickness → Chapter

25 -	Gearbox housing

26 -

Spring

q	Installation position → Fig.

27 -	Locking collar

28 -	Synchro-hub

29 -	Locking pieces (3x)

q	Installation position → Fig.

Pulling out tapered roller bearing outer race A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 46...58 mm, e.g. -Kukko 21/7-   Note After pulling out, check shim for damage and renew if necessary.

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

Pulling off tapered roller bearing inner race –  First remove circlip. –  Before setting up puller, position thrust piece -VW 431- and thrust plate -40-105- on output shaft.

Pressing off 5th and 6th gear synchro-hub/locking collar with 6th speed selector gear –  First remove circlip.

Pressing off sleeve -A- with reverse selector gear –  First remove circlip.

Pressing off reverse gear synchro-hub –  First remove circlip. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pulling off tapered roller bearing inner race –  Before applying puller, place thrust plate -30-11- on output shaft.

Installation position of reverse gear synchro-hub Stop -arrow A- for reverse gear locking collar faces towards gear teeth on output shaft -arrow B-.

Pressing on reverse gear synchro-hub –  Fit circlip.

Pressing on sleeve -A- Installation position: Wide shoulder faces towards reverse selector gear –  Fit circlip.

Checking 5th and 6th 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
5th and 6th gear	1.0…1.7 mm	0.5 mm

Dismantling and assembling 5th and 6th gear locking collar and 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 5th and 6th 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.

Pressing on 5th and 6th gear locking collar/synchro-hub On some versions the outer diameter of the locking collar is chamfered. Installation position: Chamfer on outer diameter of locking collar faces towards 5th speed selector gear. –  Fit circlip.

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. –  Select circlip from table. For part numbers, refer to → Electronic parts catalogue. Circlips available

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	1.95

Pressing on tapered roller bearing inner race

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 –  Support gearbox housing with thrust piece -2050- directly below bearing mounting.