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 408 A-

t	Press tool -VW 412-

t	Tube -VW 416 B-

t	Press tool -VW 433-

t	Press tool -VW 454-

t	Support plate -VW 801-

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

t	Adapter -V.A.G 1582/7-

t	-1-Internal puller -Kukko 21/7-

t	-3-Splitter -Kukko 17/2-

t	-4-Counter-support -Kukko 22/2-

t	Thrust plate -40-105-

t	Drift sleeve -41-501-

t	Tube -2040-

t	Thrust piece -2050-

t	Thrust plate -3074-

t	Extension -3161-

Input shaft - exploded view of components

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. Table of adjustments → Chapter.

1 -	Gearbox housing

2 -

Shim

q	Determining thickness → Chapter

3 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -

Circlip

q	When tapered roller bearing → Item or input shaft → Item are renewed: determine thickness of required circlip → Fig.

5 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

6 -	5th gear wheel

q	Pressing off → Fig.

q	Pressing on → Fig.

7 -	3rd/4th and 6th gear wheels

q	Pressing off → Fig.

q	Pressing on → Fig.

8 -	Input shaft

q	Adjusting → Chapter

9 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

10 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	On gearboxes from manufacture date 06 04 0: secured with locking plate → Item and bolt → Item

q	Installation position on gearboxes from manufacture date 06 04 0 → Fig.

q	Pressing in → Fig.

q	Renew bolt for locking plate and tighten to 12 Nm.

11 -	Clutch housing

q	On gearboxes from manufacture date 06 04 0: with additional threaded hole and recess for locking plate to secure tapered roller bearing outer race → Item

Pulling tapered roller bearing outer race out of gearbox housing A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Place thrust piece -2050- directly under bearing mounting to support gearbox housing.

Pulling off tapered roller bearing inner race A -  Soft jaws/vice –  First remove circlip. –  Before applying puller, place extension -3161- and thrust plate -40-105- on input shaft.

Pressing off 5th gear wheel A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pressing off 3rd/4th and 6th gear wheels

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

Pressing on 3rd/4th and 6th gear wheels –  Heat gear wheel to approx. 100 °C.   WARNING Wear protective gloves. –  Press on gear wheel quickly so that the heat is not immediately transferred to the input shaft.

Pressing on tapered roller bearing inner race

Pressing on 5th gear wheel

Pressing on tapered roller bearing inner race

Determining thickness of circlip –  Determine the thickest circlip which will just fit and install it.

Circlips available (in mm) → Note
1.79	1.89	1.98
1.83	1.92
1.86	1.95

1)  Part No.; for allocation refer to → Parts catalogue

Pulling tapered roller bearing outer race out of clutch housing A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-

Installation position of tapered bearing outer race in clutch housing - gearboxes from manufacture date 06 04 0 l  The recesses for locking plate ( → Fig.) on tapered roller bearing outer race -arrow A- and clutch housing -arrow B- must align.

Pressing in tapered roller bearing outer race Gearboxes from manufacture date 06 04 0: –  After pressing in, check that the locking plate -A- can be inserted in the recess. l  The input shaft must be inserted before installing and securing the locking plate.