Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Press tool -VW 408 A-

t	Thrust plate -VW 447 H-

t	Thrust pad -VW 512-

t	Press tool -VW 407-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Tube -VW 422-

t	Thrust plate -VW 447 i-

t	Press tool -VW 412-

t	Drift sleeve -30 - 100-

t  -1-internal puller-Kukko 21/6- t  -3- Splitter -Kukko 17/2- t  -4- Counter-support -Kukko 22/2-

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

Pulling off inner race for small tapered roller bearing A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pressing on inner race for small tapered roller bearing

Pulling out tapered roller bearing outer race A -  Internal puller 37 … 46 mm -Kukko 21/6- B -  Counter-support -Kukko 22/2-

Pressing in tapered roller bearing outer race

Removing circlip -1- from groove A -  Protective glove   WARNING Risk of accident. Make sure the circlip does not spring off.

Pressing off synchronising hub –  After removing circlip, press off synchronising hub and 3rd speed selector gear.

Inserting circlip

Checking 3rd and 4th gear synchro-ring for wear –  Press synchro-ring onto taper of selector gear and measure gap dimension -a- with feeler gauge. l  Specified gap: 1.1 ... 1.7 mm. l  Wear limit 0.5 mm.

Assembling locking collar and synchro-hub for 3rd and 4th gear Installation position: l  Shorter splines beneath all-round groove -bottom arrow- facing 3rd gear. l  Groove at end face -top arrow- facing 4th gear.

Assembling locking collar and synchro-hub l  Locking collar is pushed over synchronising hub. –  Insert locking pieces and install springs offset at 120°. l  Angled end of spring must locate in hollow locking piece.

Pressing on 3rd and 4th gear synchronising hub with locking collar –  Insert the circlip → Fig.. –  Check axial clearance of 3rd speed selector gear; if necessary press back synchronising hub until it makes contact with circlip → Fig..