Audi Workshop Service and Repair Manuals

Exploded view - dismantling and assembling output shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust pad -VW 512-

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

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

t	Adapter -V.A.G 1582/5-

t	Thrust plate -VW 402-

t	Thrust piece -32 - 111-

t	Press tool -VW 408 A-

t	Press tool -VW 409-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Thrust ring -VW 429-

t	Tube -VW 415 A-

t	Thrust plate -VW 447 H-

t	Press tool -VW 454-

t	Installing sleeve -VW 455-

t	Drift sleeve -41 - 501-

t  -1-Internal puller, e.g. -Kukko 21/6-

t  -4-counter support, e.g. -Kukko 22/2- t  -1-Two-arm puller e.g. -Kukko 20/10- with 250 mm long hooks

t

The output shaft is dismantled as follows: - Position splitter under 2nd speed selector gear ( → Item) and press off as described in → Fig.. - Remove circlip → Item. Fit two-arm puller under bearing mounting ( → Item) and pull off 1st and 2nd gear locking collar and synchronising hub as shown in → Fig.

t	Refer to technical data → Chapter when installing new gears or a new output shaft.

t	Always renew both tapered roller bearings together.

t	Do not over-stretch circlip → Item. Always renew circlips which have been damaged or over-stretched.

1 -	Hexagon nut

q	25 Nm and turn 90° further

q	4 nuts for bearing mounting

2 -	Clutch housing

3 -

Shim

q	For output shaft

q	Determining thickness - Adjusting output shaft → Chapter

q	Table of adjustments → Chapter

4 -	Small tapered roller bearing outer race

q	Removing → Fig.

q	Pressing in → Fig.

5 -	Small tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

6 -	Output shaft

q	Is paired with final drive gear, only renew as a set

q	Adjusting → Chapter

7 -	Large tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

8 -

O-ring

q	Place O-rings (4x) on bolts for bearing mounting

9 -	Bearing mounting

q	With large tapered roller bearing outer race and bolts

q	Only renew outer race together with large tapered roller bearing and bearing mounting

10 -	Thrust washer

q	Shoulder on thrust washer faces towards large tapered roller bearing inner race → Item

11 -	1st speed selector gear

q	Modified 1st gear synchromesh from gearbox build date 02 05 0 → Chapter

12 -	Needle bearing

q	For 1st gear

13 -	1st gear synchro-ring

q	Checking for wear → Fig.

q	Identification → Fig.

q	Distinguishing 1st and 2nd gear synchro-rings → Fig.

q	Modified 1st gear synchromesh from gearbox build date 02 05 0 → Chapter

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

q	Press off together with bearing mounting → Item after removing circlip → Fig.

q	Dismantling → Fig.

q	Assembling locking collar/synchronising hub → Fig. and → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

q	Modified 1st gear synchromesh from gearbox build date 02 05 0 → Chapter

15 -

Circlip

16 -	2nd gear synchro-ring

q	Checking for wear → Fig.

q	Identification → Fig.

q	Distinguishing 1st and 2nd gear synchro-rings → Fig.

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

17 -	Outer ring

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

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

18 -	Synchro-ring

q	Inner ring

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

19 -	2nd speed selector gear

q	Installation position → Fig.

20 -	Needle bearing

q	For 2nd gear

21 -	Thrust washer

22 -	Sleeve for 3rd gear needle bearing

q	Pressing off with 2nd speed selector gear → Fig.

q	Pressing on → Fig.

23 -	Needle bearing

q	For 3rd gear

24 -	3rd speed selector gear

25 -	3rd gear synchro-ring

q	Checking for wear → Fig.

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

q	Pressing off with 2nd speed selector gear ( → Item) and 3rd speed selector gear ( → Item) → Fig.

q	Dismantling → Fig.

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

q	Assembling locking collar/synchronising hub → Fig. and → Fig.

q	Pressing on → Fig.

27 -

Sleeve

q	For 4th gear needle bearing

q	Pressing off with locking collar and synchronising hub for 3rd and 4th gear ( → Item) → Fig.

q	Pressing on → Fig.

28 -	Needle bearing

q	For 4th gear

29 -	4th gear synchro-ring

q	Checking for wear → Fig.

30 -	4th speed selector gear

31 -	Thrust washer

32 -	Needle bearing

q	For output shaft

q	Removing and installing → Fig.

33 -	Gearbox housing

34 -

Sleeve

q	For needle bearing → Item

q	Pressing off → Fig.

q	Pressing on → Fig.

35 -	5th gear wheel

q	Removing and installing → Chapter

36 -	Dished spring

q	Installation position →

37 -

Bolt

q

M10 x 1

q	Tightening torque → Item

q	Always renew

q	Fitted piece on bolt head holds dished spring in position

Pulling out small tapered roller bearing outer race A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2-

Pressing in small tapered roller bearing outer race

Pulling off small tapered roller bearing inner race -A- Soft jaws/vice –  Fit adapter and apply tension to it behind the bearing rollers, then turn bearing and re-tension adapter.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchronising hub/locking collar; 2nd, 3rd and 4th speed selector gears with needle bearing sleeve for output shaft A -  Splitter 22...115 mm, e.g. -Kukko 17/2- B -  Hexagon bolt, 17 mm (M10 x 20) –  Position splitter under 2nd speed selector gear → Item and press off.   Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.

Pressing off locking collar with synchronising hub and bearing mounting –  First remove circlip -arrow-.

Pulling off large tapered roller bearing inner race -A- Soft jaws –  Before applying puller, insert an M10 x 20 hexagon bolt in hole in output shaft.

Pressing on large tapered roller bearing inner race -A- Thrust washer –  Fit thrust washer before pressing on inner race. Shoulder faces towards inner race.

Checking synchro-ring for wear –  Press synchro-ring onto tapered seat on selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Specification	Wear limit
1st gear1) 3rd gear 4th gear	1.0…1.7 mm 1.0…1.7 mm 1.0…1.7 mm	0.5 mm
l  1) For 1st gear synchromesh up to gearbox build date 01 05 00

Dismantling and assembling 1st and 2nd gear locking collar and synchronising hub up to gearbox build date 01 05 00 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. The wider shoulder of the synchronising hub -arrow A- and the outer splines of the locking collar -arrow B- face in opposite directions after assembly. Recesses for locking pieces in synchronising hub and locking collar must align.

Assembling 1st and 2nd gear locking collar/synchronising hub l  Locking collar is pushed over synchronising 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/synchronising hub Teeth on locking collar -arrow 1- point to splines for 3rd/4th gear synchronising hub -A-. The wide shoulder of the synchronising hub -arrow 2- then faces towards 1st gear -B-.

Pressing on 1st and 2nd gear locking collar/synchronising hub   Note Before pressing on, place 1st gear synchro-ring on 1st speed selector gear.

Identification of 1st and 2nd gear synchro-rings t  1st gear synchro-ring: 3 x ground down 1/2 teeth -arrow- t  2nd gear synchro-ring: 3 x ground down 1/2 teeth -arrow- or 2 x ground down 1/2 teeth Only the version with “2 x ground-down 1/2 teeth” is available as a spare part for the 2nd gear synchro-ring.

Distinguishing 1st gear synchro-rings (up to gearbox build date 01 05 00) and 2nd gear synchro-rings t  1st gear synchro-ring: no recesses t  2nd gear synchro-ring: three recesses -arrows-

Checking 2nd 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-	Specification	Wear limit
2nd gear	1.2 ... 1.8 mm	0.5 mm

Installation position of outer ring The lugs -arrows- face towards 1st gear -A-.

Checking inner ring for wear –  Press inner ring onto tapered seat on 2nd speed selector gear and measure gap -a- using a feeler gauge.

Gap -a-	Specification	Wear limit
2nd gear	0.75 ... 1.25 mm	0.3 mm

Installation position of synchro-ring (inner ring) -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-.

Installation position of 2nd speed selector gear The higher shoulder -A- faces towards 1st gear -B-. The recesses in the shoulder -arrows- engage on the lugs on the outer ring (arrow → Fig.).

Fitting thrust washer and pressing on needle roller bearing sleeve for 3rd gear.

Dismantling and assembling 3rd and 4th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchronising hub –  Push locking collar over synchronising hub. Recesses for locking pieces in synchronising hub and locking collar must align.

Assembling 3rd and 4th gear locking collar/synchronising hub Locking collar is pushed over synchronising hub. –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Installation position of 3rd and 4th gear locking collar/synchronising hub Chamfer -arrow- faces towards 4th gear.

Pressing on 3rd and 4th gear synchronising hub with locking collar

Pressing on sleeve for 4th gear needle bearing –  Install needle roller bearing, synchro-ring and 4th speed selector gear. –  Fit thrust washer over 4th speed selector gear.

Pressing on sleeve for needle bearing/output shaft