Audi Workshop Service and Repair Manuals

Notes:

• ◆ General repair instructions
• ◆ When installing new gears => Technical data, Page 00-3

• Gearbox housing
• ◆ Servicing
• Needle bearing for input shaft
• ◆ Pulling out => Fig.34-117
• ◆ Driving in => Fig.34-117
• Circlip
• ◆ For needle bearing
• Circlip
• ◆ For input shaft

• Thrust washer
• Needle bearing for 4th gear
• ◆ Mark before removing
• ◆ Do not interchange with needle bearing for 3rd gear
• ◆ Oil with gear oil before installing
• 4th speed sliding gear
• ◆ Before installing, insert spring
  => Fig.1
• ◆ After installing, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)
• Synchro-ring for 4th gear
• ◆ Checking for wear => Fig.2

• Locking collar
• ◆ Paired with synchro-hub
• ◆ Mark before removing => Page 34-57
• Circlip
• ◆ Re-determine thickness when renewing synchro-hub => Fig.3
• ◆ Installation position: ends align with groove of synchro-hub
• Synchro-hub for 3rd and 4th gear
• ◆ Pressing off => Fig.4
• ◆ Installation position: => Fig.5
• ◆ Pressing on => Fig.6
• Synchro-ring for 3rd gear
• ◆ Checking for wear => Fig.2
• ◆ Synchro-ring with molybdenum coating

• 3rd speed sliding gear
• ◆ Before installing, insert spring
  => Fig.1
• ◆ After pressing on -item 11-, check axial clearance with a feeler gauge
  (0.15 ... 0.35 mm)
• Needle bearing for 3rd gear
• ◆ Mark before removing
• ◆ Do not interchange with needle bearing for 4th gear
• ◆ Oil with gear oil before installing
• Input shaft
• Spring pin
• ◆ Always renew
• ◆ Drive in when renewing input shaft
  => Fig.7

• Cylinder roller bearing for input shaft
• ◆ Pressing out => Fig.34-96
• ◆ Pressing in => Fig.34-97
• Bearing plate
• ◆ Servicing => Page 34-90
• Inner race for cylinder roller bearing
• ◆ Take off and fit by hand
• Circlip
• Thrust washer for needle bearing for 6th gear
• ◆ Not fitted on 5-speed gearbox
• ◆ Installation position: shoulder towards circlip, smooth contact surface towards needle bearing
  => Page 34-71

• Needle bearing for 6th gear
• ◆ Not fitted on 5-speed gearbox
• ◆ Oil with gear oil before installing
• 6th speed sliding gear
• ◆ Not fitted on 5-speed gearbox
• ◆ Before installing, insert spring
  => Fig.1
• ◆ After installing, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)
• Synchro-ring for 6th gear
• ◆ Not fitted on 5-speed gearbox
• ◆ Checking for wear => Fig.2
• Synchro-hub for 5th and 6th gear
• ◆ Pulling off => Page 34-58
• ◆ Driving on => Page 34-72
• ◆ Installation position: projecting hub towards 5th speed sliding gear

• Locking collar
• ◆ Paired with synchro-hub
• ◆ Mark before removing => Page 34-57
• Synchro-ring for 5th gear
• ◆ Checking for wear => Fig.2
• 5th speed sliding gear
• ◆ Before installing, insert spring
  => Fig.1
• ◆ After installing, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)
• Inner race for 5th speed sliding gear
• ◆ Pulling off => Page 34-58
• ◆ Driving on => Page 34-75
• Needle bearing for 5th gear
• ◆ Oil with gear oil before installing

• 1st four-point bearing inner race for input shaft
• ◆ Pulling off => Page 34-56
• ◆ Driving on
• End cover
• ◆ Servicing => Page 34-80
• 2nd four-point bearing inner race for input shaft
• ◆ Pulling off => Page 34-55
• ◆ Driving on => Page 34-76
• Multi-point socket head bolt
  - 150 Nm
• ◆ Loosening and tightening
  => Page 34-55

→ Fig.1    Inserting spring in sliding gear

• ‒ Insert spring -arrow- in sliding gear, hook angled end into hole.

→ Fig.2    Checking synchro-ring for wear

• ‒ Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
• ‒ Add together results and divide by three.
• ‒ The figure calculated must not be less than 0.5 mm

→ Fig.3    Re-determining thickness of circlip

• ‒ Press synchro-hub onto stop.

Note:

Note correct installation position when pressing on =>Fig.5.

• ‒ Determine the thickest circlip that can still just be fitted.

Note:

The opening of the circlip must align with the groove in the synchro-hub.

• ‒ Determine circlip from table. Part No.

=> Parts catalogue

Circlips available

• ‒ Fit circlip.

→ Fig.4    Pressing off synchro-hub for 3rd and 4th gear

→ Fig.5    Synchro-hub installation position

• ◆ Oil groove in synchro hub -arrow 1- must align with oil drilling -arrow 2- in input shaft

→ Fig.6    Pressing on synchro-hub for 3rd and 4th gear

• ‒ Heat synchro-hub to approx. 100 °C, fit and press home.
• ‒ Fit circlip.

→ Fig.7    Driving spring pin into input shaft

• ‒ Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B- in until it touches drift.