Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Thrust plate -VW 447 H-

t	Press tool -VW 412-

t	Tube -VW 422-

t	Thrust plate -VW 401-

t	Press tool -VW 408 A-

t	Tube -VW 421-

t	Thrust plate -VW 447 i-

t	Press tool -VW 454-

t	Thrust pad -VW 510-

t	Drift sleeve -41-501-

t	-3-Splitter -Kukko 17/1-

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

t	The input shaft must be re-adjusted if the position of tapered roller bearings is affected when renewing parts. Refer to table of adjustments → Chapter.

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

1 -	Clutch housing

2 -	Tapered roller bearing outer race

q	Removing → Fig.

q	Pressing in → Fig.

3 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

4 -	Input shaft

q	Adjusting → Chapter

5 -	3rd gear wheel

q	Shoulder faces towards 4th gear

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -

Circlip

7 -	4th gear wheel

q	Pressing off with tapered roller bearing inner race and sleeve → Fig.

q	Pressing on → Fig.

q	Shoulder faces towards 3rd gear

8 -	Tapered roller bearing inner race

q	Pressing off with 4th gear wheel and sleeve → Fig.

q	Pressing on → Fig.

9 -	Thrust washer

10 -	Tapered roller bearing outer race

q	Pressing out → Fig.

q	Pressing in → Fig.

11 -

Shim

q	Determining thickness → Chapter „Adjusting input shaft“

12 -	Gearbox housing

13 -

Sleeve

q	For 5th gear needle bearing

q	Press off with 4th gear wheel and tapered roller bearing inner race → Fig.

q	Pressing on → Fig.

q	Fit thrust washer → Item before installing

14 -	Needle bearing

q	For 5th gear

15 -	5th speed selector gear

q	Pull off together with 5th gear synchronising hub → Chapter

16 -	5th gear synchro-ring

q	With cast locking pieces →

q	Checking for wear →

17 -

Spring

q	Installation position → Fig.

q	Modified spring from gearbox build date 05 11 1 → Chapter

18 -	Locking pieces (3x)

q	Installation position → Fig.

q	From gearbox build date 05 03 1, hollow locking pieces with internal recess are fitted.

19 -	5th gear synchronising hub

q	Removing and installing → Chapter

20 -	5th gear locking collar

q	Removing and installing → Chapter

21 -	Dished spring

q	Installation position →

22 -

Bolt

q

M10 x 1

q	Tightening torque → Item

q	Always renew

q	Fitted piece on bolt head holds dished spring in position

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race A -  Splitter-Kukko 17/1-

Pressing on tapered roller bearing inner race

Pressing off 4th gear wheel with tapered roller bearing and sleeve

Pressing off 3rd gear wheel

Pressing on 3rd gear wheel

Pressing on 4th gear wheel Shoulder faces towards 3rd gear.

Pressing on tapered roller bearing inner race

Fitting thrust washer and pressing on needle roller bearing sleeve for 5th gear.

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race –  Press in with shim after adjusting input shaft.

5th gear synchromesh 1 -  Springs for locking pieces 2 -  Locking collar with 3 recesses -arrows A- for locking pieces -4- 3 -  Synchronising hub 4 -  Locking pieces - Installation position: The thin extension -arrow B- faces the pointed teeth of the locking collar -2-

Assembling 5th gear locking collar/synchronising hub –  Push locking collar over synchronising hub. Pointed teeth -A- of locking collar and shoulder -B- of synchronising hub face in same direction. The recesses for the locking pieces in the locking collar and synchronising hub must be aligned → Fig.. –  Fitting locking pieces → Fig.. –  Insert springs offset by 120° underneath lug -C-. Angled ends of spring must be in front of locking pieces -arrows-.