Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 401 Thrust plate
• ◆ VW 402 Thrust plate
• ◆ VW 407 Press tool
• ◆ VW 408 A Press tool
• ◆ VW 412 Press tool
• ◆ VW 415 A Tube

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 313 Support clamp
• ◆ VW 353 Gearbox support
• ◆ VW 431 Press piece
• ◆ VW 433 Press piece
• ◆ VW 454 Press piece

Special tools and workshop equipment required

• ◆ VW 512 Press disk
• ◆ VW 516 Tube
• ◆ VW 519 Tube
• ◆ VW 771 Multi-purpose tool
• ◆ VW 801 Holding plate
• ◆ 40-105 Thrust plate

Special tools and workshop equipment required

• ◆ 40-20 Press tool
• ◆ 40-21 Press tool
• ◆ 2050 Thrust piece
• ◆ 3161 Extension
• ◆ 3235 Press
• ◆ V.A.G 1582 Taper roller bearing puller

Special tools and workshop equipment required

• ◆ V.A.G 1582/7 Grip

• ◆ 1 - Internal puller Kukko 21/7
• ◆ 1 - Internal puller Kukko 21/8
• ◆ 2 - Kukko 18/2 Puller
• ◆ 3 - Kukko 17/2 Separating device
• ◆ 4 - Counter support Kukko 22/2

Notes:

• ◆ When installing new gear wheels or a new output shaft consult technical data
  .
• ◆ If the output shaft or taper roller bearings have been renewed then carry out output shaft adjustment .

• Clutch housing
• Oil deflector ring
• Dished washer
• ◆ Pulling out => Fig. 1
• ◆ Pressing in => Fig.2
• Outer race/taper roller bearing
• ◆ Pulling out => Fig. 3
• ◆ Pressing in => Fig.4
• Taper roller bearing inner race
• ◆ Pressing off => Fig.8
• ◆ Pressing on => Fig.9

• Output shaft
• ◆ For 1st-4th gear
• ◆ Adjusting => Page 35-45
• Needle roller bearing
• ◆ For 2nd gear
• 2nd gear wheel
• Synchro-ring
• ◆ (Inner ring for 2nd gear)
• ◆ Checking for wear
  => Fig.10
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.12
• 2nd gear outer ring
• ◆ Insert in the synchro-ring (item9)
• ◆ Renew if scored
• ◆ Installation position => Fig.12
• 2nd gear synchro-ring
• ◆ Checking for wear
  => Fig.11
• ◆ Installation position => Fig.12

• 1st and 2nd gear locking collar with synchro-hub
• ◆ Pull off over bearing support after removing securing clip (item 13)
  => Fig.7
• ◆ Dismantling => Fig.13
• ◆ Assembling locking collar/synchro hub => Fig.13 and Fig.14
• ◆ Installation position => Fig.15
• ◆ Pressing on => Fig.16
• Securing clip
• 1st gear synchro-ring
• ◆ Checking for wear
  => Fig.11
• ◆ Assemble so that the recesses locate in the locking collar (item 12) locking pieces
• 1st gear outer ring
• ◆ Insert in the synchro-ring (item11), installation position
  => Fig.17
• ◆ Renew if scored

• Synchro-ring
• ◆ (1st gear inner ring)
• ◆ Checking for wear
  => Fig.10
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.18
• Needle roller bearing
• ◆ For 1st gear
• 1st gear sliding wheel
• ◆ Installation position => Fig.19
• Thrust washer
• ◆ For 1st and 4th gear
• ◆ Insert lugs on thrust washer in holes on output shaft
• Shim
• ◆ Holds thrust washer -item 19- in position on output shaft

• Needle roller bearing
• ◆ For 4th gear
• 4th gear wheel
• 4th gear synchro-ring
• ◆ Checking for wear
  => Fig.22
• Locking collar with 3rd and 4th gear synchro-hub
• ◆ Pull off by pulling off 4th gear wheel after removing the circlip (item 25)
  => Fig.6
• ◆ Dismantling => Fig.13
• ◆ Installation position locking collar/synchro-hub => Fig.20
• ◆ Assembling locking collar/synchro hub => Fig.13 and Fig.14
• ◆ Pressing on => Fig.21
• Securing clip

• 3rd gear synchro-ring
• ◆ Checking for wear
  => Fig.11
• Outer ring for 3rd gear
• ◆ Insert in the synchro-ring (item 26), installation position
  => Fig.17
• ◆ Renew if scored
• Synchro-ring
• ◆ (3rd gear inner ring)
• ◆ Checking for wear
  => Fig.10
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.18
• Needle roller bearing
• ◆ For 3rd gear
• 3rd gear wheel
• ◆ Installation position => Fig.19

• Taper roller bearing inner race
• ◆ Pulling off => Fig.5
• ◆ Pressing on => Fig.23
• Securing clip
• ◆ Redetermine thickness if taper roller bearing -item 6- or output shaft -item 31- are replaced =>Fig.24
• Outer race/taper roller bearing
• ◆ Pulling out => Fig.25
• ◆ Pressing in => Fig.26
• Shim
• ◆ Determining thickness => Page 35-45
• Gearbox housing

→ Fig.1    Pulling dished washer -A- out from output shaft

→ Fig.2    Pressing dished washer -A- in output shaft onto stop

→ Fig.3    Pulling taper roller bearing outer race out from gearbox housing

A - Counter support, e.g. Kukko 22/2

A - Internal puller 56 ... 70 mm, e.g. Kukko 21/8

→ Fig.4    Pressing taper roller bearing outer race into gearbox housing

• ‒ Support gearbox housing with press tool 40-20 directly below bearing mounting.

→ Fig.5    Pulling off taper roller bearing inner race

• ‒ Before fitting puller, position press piece VW 431 in output shaft and set thrust plate 40-105 on it.

→ Fig.6    Pulling off 3rd and 4th gear synchro-hub/locking collar over 4th gear wheel

• ‒ First remove securing clip.

A - Puller, e.g. Kukko 18/2

B - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.7    Pressing off 1st and 2nd gear locking collar and synchro-hub

After removing securing ring press 2nd gear sliding wheel and locking collar/synchro-hub off together.

→ Fig.8    Pulling off taper roller bearing inner race

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.9    Pressing on taper roller bearing inner race

→ Fig.10    Checking inner ring for 1st, 2nd and 3 gear for wear

• ‒ Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.

→ Fig.11    Checking 1st, 2nd and 3rd gear synchro-rings for wear

• ‒ Press synchro-ring, outer-ring and inner-ring onto gear wheel cone and measure gap "a" with feeler gauge.

→ Fig.12    Installation position of outer ring, inner ring and 2nd gear synchro ring

• ‒ Place inner ring -A- on 2nd gear wheel.

Angled lugs (arrow 1) point towards outer ring -B-.

• ‒ Fit outer ring -B-.

Lugs (arrow 2) engage in gear wheel recesses (arrow 3).

• ‒ Fit synchro-ring -C-.

The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.

→ Fig.13    Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub

•     1 -    Spring
•     2 -    Locking piece
•     3 -    Locking collar
•     4 -    Synchro-hub

• ‒ Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.

→ Fig.14    Assembling 1st and 2nd gear locking collar/synchro-hub

The locking collar has been pushed over the synchro-hub.

• ‒ Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow locking piece.

→ Fig.15    Installation position of 1st and 2nd gear locking collar/synchro-hub

Identification groove -arrow 1- and narrow collar -arrow 2- of synchro-hub point towards 1st gear.

→ Fig.16    Pressing on 1st and 2nd gear locking collar/synchro-hub

→ Fig.17    Installation position for 1st or 3rd gear outer ring

Lugs (arrows) face towards synchro-hub/locking collar -A-

→ Fig.18    Installation position synchro-ring (inner ring) -A-

The lugs (arrows 1) engage in the recesses (arrow 2) in the synchro-ring -B-.

→ Fig.19    Installation position 1st and 3rd gear wheel

The higher shoulder -A- faces toward 2nd or 4th gear -B-. The recesses in the shoulder (arrows) engage in the lugs of the outer ring (arrow => Fig. 17)

→ Fig.20    Installation position 3rd and 4th gear locking collar/synchro-hub

The wider shoulder of the synchro-hub (arrow) faces towards 3rd gear.

→ Fig.21    Pressing on 3rd and 4th gear synchro-hub with locking collar

→ Fig.22    Checking synchro-ring for wear

• ‒ Press synchro-ring onto the gear wheel cone and measure gap "a" with feeler gauge.

→ Fig.23    Pressing on taper roller bearing inner race

→ Fig.24    Determining thickness of circlip

• ‒ Determine the thickest securing clip which will still fit and install it.

The following securing clips are available:

→ Fig.25    Pulling taper roller bearing outer race out from gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.26    Pressing taper roller bearing outer race into gearbox housing

• ‒ Fit shim under outer race.
• ‒ Support gearbox housing with press piece 2050 directly below bearing support.