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	Tube -VW 415 A-

t	Tube -VW 422-

t	Spacer sleeve -VW 472/2-

t	Tube -VW 516-

t	Drift sleeve -30 - 100-

t	Tube -2010-

t	Thrust piece -3002-

t	Thrust piece -T10080-

t	Thrust piece -T10081-

t	Thrust block -T10083-

t	Thrust plate -T10084 A-

t	-1-Internal puller 30...37 mm, e.g. -Kukko 21/5-

t	-2-puller, e.g. -Kukko 18/1-

t	-3-Splitter 12...75 mm, e.g. -Kukko 17/1-

t	-4-Counter support, e.g. -Kukko 22/1-

t	Refer to technical data when installing new gears → Chapter.

t	Lubricate all bearings, selector gears and synchro-rings on input 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 -

Circlip

q	Always renew

q	Determining thickness → Anchor

2 -	Locking collar with synchronising hub for 5th gear

q	Removing and installing ⇒ from Page → Chapter

q	Dismantling → Fig.

q	Assembling 5th gear locking collar/synchronising hub → Fig. → Fig.

q	Installation position → Fig.

3 -	5th gear synchro-ring

q	Checking for wear → Fig.

4 -	5th speed selector gear

5 -	Needle bearing

q	For 5th gear

q	Renew together with → Item

6 -

Sleeve

q	For 5th gear needle bearing

q	Renew together with → Item

q	Press off with bearing mounting/grooved ball bearing → Fig..

q	Pressing on → Fig.

7 -	Gearbox housing

8 -	Bearing mounting with grooved ball bearings

q	If bearing mounting is separated from gearbox housing, it must always be renewed

q	Only renew grooved ball bearings together with bearing mounting.

q	Pressing off → Fig.

q	Pressing on → Fig.

9 -	Input shaft

10 -	Needle bearing

q	For 3rd gear

11 -	3rd speed selector gear

12 -	3rd gear synchro-ring

q	Checking for wear → Fig.

13 -

Circlip

q	Fitted on gearboxes with code letters EYX and FDM

q	Modification: not fitted from 07.01 onwards

q	Pressing out → Fig.

q	Fitting → Fig.

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

q	Press off with 3rd speed selector gear → Fig.

q	Dismantling → Fig.

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

q	Assembling → Fig.

q	Pressing on → Fig.

15 -

Circlip

q	Fitted on gearboxes with code letters EYX and FDM

q	Modification: not fitted from 07.01 onwards

q	Pressing out → Fig.

q	Fitting → Fig.

16 -	4th gear synchro-ring

q	Checking for wear → Fig.

17 -	4th speed selector gear

18 -	Needle bearing

q	For 4th gear

q	Modification: from 07.01 onwards, needle bearing is fitted with additional sleeve; allocate via → Electronic parts catalogue

q	Pressing off sleeve for needle bearing → Anchor

q	Pressing on sleeve for needle bearing → Fig.

19 -	Thrust washer

20 -	Inner race for roller bearing

q	Pull off together with 3rd speed selector gear → Fig.

q	Pressing on → Fig.

21 -

Circlip

q

Renew

q	Determining thickness → Fig.

22 -	Roller bearing

q	With circlip

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Installation position: Circlip in bearing faces towards input shaft

23 -	Clutch housing

24 -

Spring

q	Installation position → Fig.

25 -	Locking collar for 3rd and 4th gear

26 -	Synchronising hub for 3rd and 4th gear

27 -	Locking pieces (3x)

28 -

Spring

q	Installation position → Fig.

29 -	Locking pieces (3x)

30 -	5th gear synchronising hub

31 -	5th gear locking collar

32 -	Check ring

q	Prevents locking pieces from moving out

q	Removing → Fig.

q	Installing → Fig.

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 22/1- B -  Internal puller 30 ... 37 mm, e.g. -Kukko 21/5-

Pressing roller bearing into clutch housing –  Support clutch housing using tube -VW 415 A- (not visible in diagram) directly under bearing mounting. –  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.

Pressing off bearing mounting and grooved ball bearings –  Slide locking collar for 1st and 2nd gear onto 2nd gear. –  Slide in thrust plate -T10084 A- sideways until it contacts input shaft. –  Insert centralising pins in thrust piece -T10081- into bores in input and output shafts.

Pulling off roller bearing inner race with 4th speed selector gear –  First remove circlip. –  Clamp splitter-B- behind driving teeth (not dog teeth) on 4th gear. A -  Puller, e.g. -Kukko 18/1- B -  Splitter 12...75 mm, e.g. -Kukko 17/1- C -  Jaw protectors   Note

From gearbox build date 07.01 onwards, roller bearing inner race can be pressed off together with 4th speed selector gear, locking collar and synchronising hub for 3rd and 4th gear and 3rd speed selector gear.

Removing circlip -1- from groove A -  Protective glove   WARNING Prevent circlip from springing off suddenly.

Pressing off locking collar with synchronising hub for 3rd and 4th gear –  After removing the circlip, press off 3rd speed selector gear and locking collar/synchronising hub together.

Dismantling and assembling 3rd and 4th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. The deeper recesses -arrow A- for the locking pieces in the synchronising hub must align with the recesses -arrow B- in the locking collar.

Assembling 3rd and 4th gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces in the deeper slots -arrows- and install springs off-set by 120°. Angled end of spring must locate in hollow locking piece.

Installation position of 3rd and 4th gear locking collar/synchronising hub The groove on the top -arrow- points towards 4th gear.

Checking 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
3rd, 4th and 5th gear	1.1 ... 1.7 mm	0.5 mm

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

Inserting circlip

From gearbox build date 07.01: Pressing on sleeve -A- for 4th gear needle bearing –  After pressing on sleeve -A-, install 4th gear needle bearing with selector gear for 4th gear and thrust washer.

Pressing on roller bearing inner race -A-

Determining thickness of circlip –  Insert a 2.0 mm thick circlip -A- in groove of input shaft and press upwards -arrow-. –  Measure gap between inner race -B- and fitted circlip -A- using feeler gauge -C-. –  Remove circlip fitted for measurement. –  Select circlip from table. The following circlips are available:

Measured value (mm)	Circlip thickness (mm)	Axial clearance (mm)
0.05…0.10	2.0	0.05…0.15
0.15…0.20	2.1	0.05…0.15
0.25…0.30	2.2	0.05…0.15
0.35…0.40	2.3	0.05…0.15
0.45…0.50	2.4	0.05…0.10

Note Select locking pieces from → Electronic parts catalogue.

Pressing on bearing mounting with grooved ball bearing –  Heat bearing mounting to approx. 100°C before pressing on.

Pressing on sleeve -A- for 5th gear needle roller bearing

Detaching check ring –  Unclip hooks -A- of check ring from synchronising hub using a screwdriver.

Dismantling and assembling 5th gear locking collar and synchronising hub 1 -  Spring 2 -  Locking piece 3 -  Synchronising hub  -  Installation position: the groove on the top -arrow A- and the wide collar -arrow B- face the 5th gear 4 -  Locking collar 5 -  Check ring –  Push locking collar over synchronising hub. The deeper recesses -arrow C- for the locking pieces in the synchronising hub must align with the recesses -arrow D- in the locking collar.

Assembling 5th gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces in the deeper recesses -arrows- and install springs 120° off-set. Angled end of spring must locate in hollow locking piece.

Installing check ring –  Push check ring onto tube -2010-. –  Insert check ring together with tube -2010- into 5th gear synchronising hub/locking collar (observe installation position → Fig.). Hooks -arrow 1- engage in slots -arrow 2- for locking pieces in synchronising hub. –  Push check ring downwards until hooks engage.