Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Press tool -VW 432-

t	Drift sleeve -40 - 21-

t  -1-Internal puller 30...37 mm, e.g. -Kukko 21/5- t  -4-Counter support, e.g. -Kukko 22/1-

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

t	Lubricate all bearings, selector gears and synchro-rings on output 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 -	Clutch housing

2 -	Roller bearing

q	With circlip

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Installation position: the circlip in the bearing faces the output shaft

3 -	Output shaft

q	If an inner race has been fitted as bearing seat for roller bearing → Item, it is not possible to detach it from output shaft.

q	Check bearing seat / roller bearing inner race for scoring or other damage.

q	If you detect scoring or other damage to the bearing seat / inner race, renew both output shaft and roller bearing.

4 -	4th gear wheel

q	Installation position: Collar faces 3rd gear → Fig.

5 -

Circlip

6 -

Circlip

7 -	3rd gear wheel

q	Installation position: Collar faces 4th gear → Fig.

8 -

Circlip

9 -	2nd speed selector gear

10 -	Needle bearing

q	For 2nd gear

11 -	Inner ring for 2nd gear

q	Checking for wear → Fig.

q	Installation position → Fig.

12 -	Outer ring for 2nd gear

q	Fit on inner ring → Item

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

q	Installation position → Fig.

13 -	2nd gear synchro-ring

q	Checking for wear → Fig.

q	Installation position → Fig.

14 -	Locking collar with synchronising 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/synchronising hub → Fig. and → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

15 -

Circlip

q	Pressing out → Fig.

q	Fitting → Fig.

16 -	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

17 -	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

18 -	Inner ring for 1st gear

q	Checking for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

19 -	Needle bearing

q	For 1st gear

20 -	1st speed selector gear

q	Installation position → Fig.

21 -	Bearing mounting with grooved ball bearings

q	Only renew grooved ball bearings together with bearing mounting.

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

q	Pressing off → Fig.

q	Pressing on → Fig.

22 -	Gearbox housing

23 -	5th gear wheel

q	Installation position: Collar faces gearbox housing cover ⇒ Page →

24 -

Circlip

q	Always renew

q	Determining thickness → Anchor

25 -

Spring

q	Installation position → Fig.

26 -	Locking collar

27 -	Synchronising hub

28 -	Locking pieces (3x)

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.

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

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

Installation position of 3rd and 4th gear wheel –  Fit 4th gear wheel -A- onto output shaft. Installation position: Collar -arrow 1- faces 3rd gear wheel -B-. –  Fit circlips -2- and -3-. –  Fit 3rd gear wheel -B- onto output shaft. Installation position: Collar -arrow 2- faces 4th gear wheel -A-. –  Fit circlip -1-.

Checking 1st and 2nd gear inner ring 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 and 2nd gear	0.75 ... 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-ring 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 and 2nd 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 tabs -arrow 1- point towards the outer ring -B-. –  Fit outer ring -B-. The tabs -arrow 2- lock in the recesses -arrow 3- of the selector gear. –  Fit synchro-ring -C-. The recesses -arrow 4- locate on the tabs -arrow 1- of the inner ring -A-.

Dismantling and assembling 1st and 2nd gear locking collar and synchronising hub 1 -  Spring 2 -  Locking collar 3 -  Synchronising hub 4 -  Locking piece –  Push locking collar over synchronising hub. Installation position: After assembly, the groove on the top -arrow A- and the higher shoulder -arrow B- on the synchronising hub will face towards the external splines on the locking collar -arrow C-. The deeper recesses -arrow D- for the locking pieces in the synchronising hub must align with the recesses -arrow E- in the locking collar.

Assembling 1st and 2nd gear locking collar/synchronising hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces in deeper recesses -arrows- and install springs so they are offset 120°. Angled end of spring must locate in hollow locking piece.

Pressing on 1st and 2nd gear locking collar/synchronising hub Installation position: Groove for selector fork in locking collar points towards 1st gear; reverse gear splines point towards 2nd gear. –  Turn synchro-ring so that grooves align with locking pieces.

Inserting circlip –  Fit 1st gear synchro-ring in locking collar/synchronising hub.

Installation position of outer ring for 1st gear The lugs -arrows- face the gear teeth of the reverse gear

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

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