Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st - 4th gear

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 408A-

t	Press tool -VW 412-

t	Tube -VW 415A-

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Press tool -VW 431-

t	Press tool -VW 433-

t	Press tool -VW 454-

t	Thrust pad -VW 512-

t	Tube -VW 516-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Support plate -VW 801-

t	Thrust plate -40 - 105-

t	Sleeve from engine and gearbox support supplement -VW 540/1 B-

t	Drift sleeve -40 - 20-

t	Press tool -40 - 21-

t	Thrust piece -2050-

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

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

t  -1- Kukko internal puller 21/7 and 21/8 t  -2- Puller 18/2 t  -3- Splitter 17/2 t  -4- Kukko 22/2 counter-support

Pulling dished washer -A- out of output shaft

Pressing dished washer into output shaft l  Dimension -a- = 2 mm

Pulling out tapered roller bearing outer race A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 56 ... 70 mm, e.g. -Kukko 21/8-

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with drift sleeve -40 - 20- directly below bearing mounting.

Pulling off tapered roller bearing inner race –  Remove circlip. –  Before applying puller, fit press tool -VW 431- in output shaft and place thrust plate -40 - 105- on it.

Pulling off 3rd and 4th gear synchronising hub/locking collar with 4th speed selector gear –  Remove circlip before pulling off. A -  Puller, e.g. -Kukko 18/2- B -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing off 1st and 2nd gear locking collar and synchronising hub –  Remove circlip. –  Press off selector gear and locking collar/synchronising hub together.

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

Pressing on tapered roller bearing inner race

Checking inner ring for 1st, 2nd and 3rd gear 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, 2nd and 3rd gear	0.75...1.25 mm	0.3 mm

Checking 1st, 2nd and 3rd gear synchro-rings 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, 2nd and 3rd 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. l  The angled lugs -arrows 1- point towards outer ring -B-. –  Fit outer ring -B-. l  Lugs -arrows 2- engage in slots -arrows 3- on selector gear. –  Fit synchro-ring -C-. l  Slots -arrows 4- engage on lugs -arrows 1- on inner ring -A-.

Dismantling and assembling 1st/2nd gear and 3rd/4th gear locking collar/synchronising hub –  Take off springs -1- before dismantling. 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchronising hub –  To assemble, slide locking collar over synchronising hub. l  On 3rd and 4th gear the wider collar of the synchronising hub and the shoulder on the locking collar face in the same direction. l  Installation position: Narrower recesses in synchronising hub align with recesses in locking collar

Assembling 1st/2nd gear and 3rd/4th gear locking collar/synchronising 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.

Installation position of 1st and 2nd gear locking collar/synchronising hub l  Identification groove -arrow 1- and narrow shoulder -arrow 2- on synchronising hub point towards 1st gear.

Pressing on 1st and 2nd gear locking collar/synchronising hub –  Then install circlip.

Installation position of 1st or 3rd gear outer ring l  Lugs -arrows- face towards synchronising hub/locking collar -A-.

Installation position of synchro-ring -A- (inner ring for 1st or 3rd gear) l  Lugs -arrows 1- locate in the recesses -arrows 2- in the synchro-ring -B-.

Installation position of 1st and 3rd speed selector gear l  The higher shoulder -A- faces towards 2nd or 4th gear -B-. The recesses in the shoulder -arrows- engage on the lugs on the outer ring → Fig..

Installation position of 3rd and 4th gear locking collar/synchronising hub l  The wider shoulder on the synchronising hub -arrow- faces towards 3rd gear.

Pressing on 3rd and 4th gear synchronising hub with locking collar –  Then install circlip.

Checking synchro-ring for 4th gear for wear –  Press synchro-ring onto tapered seat on selector gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation depth	Wear limit
4th gear	1.0...1.7 mm	0.5 mm

Pressing on tapered roller bearing inner race –  Determine thickness of required circlip → Fig. and install circlip.

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it. For part number refer to → Electronic parts catalogue. The following circlips are available:

Circlip thickness (mm)
1.79	1.83	1.86
1.89	1.92	1.95
1.98

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

Pressing tapered roller bearing outer race into gearbox housing –  Fit shim below outer race. –  Support gearbox housing with thrust piece -2050- directly below bearing mounting.