Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust pad -VW 512-

t	Puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	Adapter -V.A.G 1582/5-

t	Thrust plate -VW 402-

t	Thrust piece -32 - 111-

t	Press tool -VW 409-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Drift sleeve -30 - 100-

t	Tube -VW 415 A-

t	Thrust plate -VW 447 H-

t	Press tool -VW 454-

t	Tube -2040-

t	Drift sleeve -41 - 501-

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

t  Inductive heater -VAS 6414- t  Feeler gauge

Pulling out small tapered roller bearing outer race A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2-

Pressing in small tapered roller bearing outer race

Pulling off small tapered roller bearing inner race A - Soft jaws/vice –  Fit adapter and apply tension to it behind the bearing rollers, then turn bearing and re-tension adapter.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub/locking collar; 2nd, 3rd and 4th speed selector gears with needle bearing sleeve for output shaft A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing mounting –  First remove circlip -arrow-.

Pulling off large tapered roller bearing inner race -A- - Jaw covers –  Before fitting puller, insert M10 x 20 hexagon bolt in hole in output shaft.

Pressing on large tapered roller bearing inner race -A- Thrust washer –  Fit thrust washer before pressing on inner race. Shoulder faces towards inner race.

Installation position of inner ring, outer ring and synchro-ring for 1st gear –  Place inner ring -A- on 1st speed selector gear. The angled tabs -arrow 1- point towards the outer ring -B-. –  Fit outer ring -B-. The tabs -arrow 2- lock in the recesses -arrow 3- of the selector gear. –  Fit synchro-ring -C-. The recesses -arrow 4- locate on the tabs -arrow 1- of the inner ring -A-.   Note If components are not being renewed, make sure they are re-installed on the same gear.

Checking inner ring for 1st and 2nd 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 and 2nd gear	0.75 … 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-ring 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 and 2nd gear	1.2 … 1.8 mm	0.5 mm

Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub 1 -  Spring Select correct spring from → Electronic parts catalogue. Assembling version used together with hollow locking pieces → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece Select locking pieces from → Electronic parts catalogue. Shoulders on synchro-hub are of equal width on both sides. The shoulder on one side is chamfered -arrow B-. When assembled, the chamfer on the shoulder of the synchro-hub and the external teeth on the locking collar -arrow A- face in the same direction. The recesses for the locking pieces on synchro-hub and locking collar -arrow C- must align.

Assembling locking collar/synchro-hub for 1st and 2nd gear (version with hollow locking pieces) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Assembling locking collar/synchro-hub for 1st and 2nd gear (version with solid locking pieces: no internal recess) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled ends of spring must be in front of locking pieces -arrows-.

Installation position of 1st and 2nd gear locking collar/synchro-hub Splines on locking collar -arrow- point to splines for 3rd/4th gear synchro-hub -A-.

Heat 1st and 2nd gear locking collar/synchro-hub and press on   WARNING Wear protective gloves. Turn synchro-ring so that grooves align with locking pieces.

Installation position of outer ring for 2nd gear The lugs -arrows- face towards 1st gear -A-.

Installation position of synchro-ring (inner ring for 2nd gear) -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-.

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

Pressing on sleeve for 3rd gear needle bearing

Checking 3rd and 4th gear synchro-ring 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
3rd gear 4th gear	1.0 … 1.7 mm 1.0 … 1.7 mm	0.5 mm

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring Select correct spring from → Electronic parts catalogue. Assembling version used together with hollow locking pieces → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Locking piece Select locking pieces from → Electronic parts catalogue. 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Recesses for locking pieces in synchro-hub and locking collar must align.

Assembling locking collar/synchro-hub for 3rd and 4th gear (version with hollow locking pieces) Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

Assembling locking collar/synchro-hub for 3rd and 4th gear (version with solid locking pieces: no internal recess) l  Locking collar is pushed over synchro-hub. –  Insert locking pieces and install springs offset at 120°. Angled ends of spring must be in front of locking pieces -arrows-.

Installation position of 3rd and 4th gear locking collar/synchro-hub Chamfer -arrow- faces towards 4th gear.

Heat and press on 3rd and 4th gear synchro-hub with locking collar   WARNING Wear protective gloves.

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for needle bearing/output shaft