Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft (output shaft)   Note Removing and installing gear wheels for 3rd to 6th gear and the reverse selector gear is described in → Chapter „Assembly sequence - dismantling and assembling gearbox“.

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 412-

t	Tube -VW 415 A-

t	Tube -VW 519-

t	Press tool -40 - 21-

t	Thrust piece -2050-

t	Thrust pad -3062-

t	Press tool -3118-

t	Slotted nut wrench -3155-

t	Sleeve -3144-

t	Assembly tool -3253-

t	Wheel bearing tube -3345-

t	Hot air blower -V.A.G 1416-

t	-1-Internal puller -Kukko 21/8-

t	-3-Splitter -Kukko 17/2-

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

t  Inductive heater -VAS 6414- t  Feeler gauge

Pulling outer race for tapered roller bearing out of gearbox housing –  Remove differential → Chapter. –  Fit thrust piece -2050- with the large diameter pointing towards the outer race. –  Fit threaded spindle and thrust pad of assembly tool -3253- with thrust plate -VW 401- onto gearbox housing. The outer race will be pulled out of the gearbox housing when the nut is tightened.

Heating gearbox housing in order to fit tapered roller bearing outer race –  Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100°C, with hot air blower -V.A.G 1416-.

Pressing tapered roller bearing outer race into gearbox housing –  Insert outer race only after heating gearbox housing and push into position under workshop press until heat exchange has taken place.

Pulling tapered roller bearing outer race out of bearing housing 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 bearing housing Support bearing housing with sleeve -3144- directly below bearing mounting. –  Press in outer race until limit stop.

Pressing off thrust washer for reverse selector gear A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Fit splitter-A- below thrust washer, and not below circlip. –  Then detach circlip below thrust washer.

Pressing off tapered roller bearing inner race with 2nd speed selector gear A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Caution When pressing off, make sure that only the gear teeth (driving teeth) of the selector gear and not the dog teeth contact the splitter -A-. Otherwise the dog teeth will be damaged. –  Remove circlip for tapered roller bearing inner race.

Pressing off 1st and 2nd gear synchronising hub –  Remove circlip before pressing off. –  Press off synchronising hub with 1st speed selector gear.

Pressing off tapered roller bearing inner race –  Remove circlip before pressing off. –  The outer race of the tapered roller bearing -arrow- must be fitted prior to pressing off the inner race.

Pressing on tapered roller bearing inner race –  Heat inner race to approx. 100 °C and press on. –  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.   Note The thickness of the circlips for the synchronising hubs and individual gear wheels must also be determined as shown for the tapered roller bearing. Overview for installation position of circlips → Fig.

Installation position of circlips The required circlips for the inner races of the tapered roller bearings, the synchronising hubs and individual gear wheels should be selected as shown in → Fig.. t  Circlip -1- secures the tapered roller bearing inner race.

Circlip thickness (mm)
2.50	2.56	2.62
2.53	2.59	2.65

t  Circlip -2- secures the 1st and 2nd gear synchronising hub. Identification: blue colour

Circlip thickness (mm)
1.90	2.02	2.14
1.93	2.05	2.17
1.96	2.08
1.99	2.11

t  Circlip -3- secures the tapered roller bearing inner race.

Circlip thickness (mm)

3.50

t  Circlip -4- secures thrust washer for reverse selector gear.

Circlip thickness (mm)

3.50

t  Circlip -5- secures the 3rd gear wheel.

Circlip thickness (mm)
1.90	1.98	2.06
1.94	2.02	2.10

t  Circlip -6- secures the 6th gear wheel.

Circlip thickness (mm)
1.90	2.02	2.14
1.93	2.05	2.17
1.96	2.08	2.20
1.99	2.11

–  Determine circlips according to table. For part number, refer to → Electronic parts catalogue.

Installation position of synchro-rings for 1st and 2nd gear   Note If components are not being renewed, make sure they are re-installed on the same gear. –  Fit inner ring -2- onto selector gear -1-. –  Fit intermediate ring -3-. Lug -B- must be inserted into recess -A-. –  Synchro-ring -4- fitted. Guide lugs -C- through recess -arrow-.

Checking 1st gear inner ring for wear –  Check outer contact surface -arrow- for scoring or visible traces of wear and renew if necessary. –  Press inner ring onto chamfer on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	As-new installation value	Wear limit
Inner ring for 1st gear	1.2 ... 2.0 mm	0.6 mm

Checking 1st and 2nd gear intermediate ring for wear –  Check inner friction surface of synchro-ring for scoring or visible traces of wear and renew if necessary. –  Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	As-new installation value	Wear limit
1st and 2nd gear	1.4 ... 2.0 mm	0.8 mm

Pressing on 1st and 2nd gear synchronising hub t  Installation position: Higher inside collar faces 2nd gear. l  The lugs of 1st gear synchro-ring and recesses on synchronising hub must align -arrow- when pressing on.

Assembling 1st and 2nd gear locking collar/synchronising hub –  Fit locking pieces -arrows A- into mounted synchronising hub -1-. –  Fit locking collar -2- onto synchronising hub so that the wide teeth of locking collar and synchronising hub -arrow B- coincide. –  Install circlip for 1st and 2nd gear synchronising hub. –  Install 2nd speed selector gear with needle bearing and synchro-rings.

Pressing on tapered roller bearing inner race –  Fit circlip for tapered roller bearing inner race onto pinion shaft. l  Shoulder of tube -VW 415 A- faces inner race -arrow-. Then check axial play of 1st speed and 2nd speed selector gears → Fig. and → Fig..

Checking axial play of 1st speed selector gear –  Press 1st speed selector gear -2- in direction of -arrow A- as far as the stop. –  Measure the distance between the 1st speed selector gear -2- and synchro-ring -3- using a feeler gauge-1-. Example: 2.55 mm –  Now press 1st speed selector gear -2- in direction of 2nd speed selector gear -4-. –  Measure the distance again between the 1st speed selector gear -2- and synchro-ring -3- using a feeler gauge-1-. Example: 2.15 mm l  The difference between the two measured values must be between 0.20 ... 0.50 mm.

Checking axial play of 2nd speed selector gear –  Check axial play between 2nd speed selector gear -2- and inner race of tapered roller bearing -3- using a feeler gauge-1-. l  The play must be 0.20 ... 0.50 mm.

Pressing on thrust washer for reverse selector gear –  Fit circlip -B- onto pinion shaft. –  Press on thrust washer -A- until it makes contact with circlip.