Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Tube -VW 415 A-

t	Tube -VW 416 B-

t	Thrust pad -VW 447 i-

t	Multi-purpose tool -VW 771-

t	Drift sleeve -30 - 100-

t	Thrust plate -40 - 105-

t	Drift -VW 222 A-

t	Drift -30 - 24-

t	Extractor -40 - 202-

t	-1-Internal puller -Kukko 21/4-

t	-3-Splitter -Kukko 17/2-

t	From 05.03 onwards, a new synchromesh for 3rd and 4th gear is fitted → Chapter.

t	When installing new gear wheels or input shaft, consult technical data → Chapter.

t	The position of tapered roller bearings is affected when renewing ball bearing, gearbox housing or input shaft. In this case the input shaft must be re-adjusted → Chapter.

1 -

Circlip

q

Mark

q	Installation position → Fig.

q	Determining thickness → Chapter „Adjusting input shaft“

2 -	Ball bearing

q	Removing and installing → Chapter

3 -

Circlip

q

Mark

q	Installation position → Fig.

q	Determining thickness → Chapter „Adjusting input shaft“

4 -	Gearbox housing

q	Housing manufactured from aluminium or magnesium → Item

5 -	Needle bearing

q	Secured with bolt on some gearboxes → Fig.

q	Driving out → Fig.

q	Installation position → Fig.

q	Pressing in → Fig.

q	Securing → Fig.

6 -	Input shaft

q	With oil feed sleeve

q	Knocking in oil feed sleeve → Fig.

q	Adjusting → Chapter

7 -	Needle bearing for 3rd gear

q

Mark

8 -	3rd speed selector gear

q	From 05.03 onwards, modified synchromesh → Chapter

9 -

Spring

q	From 05.03 onwards, modified synchromesh → Chapter

q	Insert in 3rd speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

10 -	Synchro-ring for 3rd gear

q	From 05.03 onwards, modified synchromesh → Chapter

q	Checking for wear → Fig.

11 -

Circlip

q

Mark

q	Installation position → Fig.

12 -	Synchronising hub for 3rd and 4th gear

q	From 05.03 onwards, modified synchromesh → Chapter

q	Higher shoulder faces towards 3rd gear

q	Pressing off → Fig.

q	Pressing on → Fig.

13 -

Circlip

q

Mark

q	Installation position → Fig.

q	Redetermine thickness if synchronising hub is replaced → Fig.

14 -	Locking collar for 3rd and 4th gear

q	From 05.03 onwards, modified synchromesh → Chapter

q	Installation position up to 05.03 → Fig.

q	Installation position from 05.03 → Fig.

15 -	Synchro-ring for 4th gear

q	From 05.03 onwards, modified synchromesh → Chapter

q	Checking for wear → Fig.

16 -

Spring

q	From 05.03 onwards, modified synchromesh → Chapter

q	Insert in 4th speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

17 -	4th speed selector gear

q	From 05.03 onwards, modified synchromesh → Chapter

18 -	Needle bearing for 4th gear

q

Mark

19 -	5th gear wheel

q	Pressing off → Fig.

q	Pressing on → Fig.

20 -

Circlip

q

Mark

q	Installation position → Fig.

q	If the 5th gear wheel is renewed redetermine thickness → Fig.

21 -	Roller bearing

q

Renew

q	Will be damaged during removal

q	Pulling out → Fig.

q	Installation position → Fig.

q	Driving in → Fig.

22 -

Sleeve

q	Made of plastic

23 -	Gearbox cover

q	Aluminium version: must only be fitted to an aluminium gearbox housing

q	Magnesium version: must only be fitted to a magnesium gearbox housing

q	Note identification markings → Fig.

q	Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-

q	Can be renewed with gearbox in vehicle → Chapter

Removing securing bolt -arrow- for needle bearing –  Unscrew securing bolt -arrow-.   Note Bolt is not fitted on all versions.

Driving out needle bearing

Installation position of needle bearing Distance -a- from lower edge of straight edge to upper edge of needle bearing = 39.5 mm   Note Measure distance from top edge of straight-edge and subtract the width of the straight-edge from the measured distance.

Pressing in needle bearing

Screwing in securing bolt -arrow-   Note Bolt is not fitted on all versions. t  Aluminium gearbox housing Tighten to 25 Nm t  Magnesium gearbox housing Tighten to 20 Nm

Knocking oil feed sleeve into input shaft

Item	Oil feed sleeve dia.	Fitting tool
A	14 mm	Drift -VW 222 A-
B	16 mm	Drift -30 - 24-

t  Installation position: Flanged edge on oil feed sleeve faces towards fitting tool. t  Installation depth: 3.5 mm below end of shaft

Pulling out roller bearing A -  Internal puller 23.5...30 mm, e.g. -Kukko 21/4- –  Before fitting internal puller the plastic sleeve inside the roller bearing must be destroyed.

Installation position of roller bearing t  Dimension -a- = 216 mm

Driving in roller bearing

Pressing off 5th gear wheel –  Remove circlip before pressing off. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing off 3rd and 4th gear synchronising hub –  Remove circlip before pressing off. –  Place splitter -A- below 3rd speed selector gear. Press off synchronising hub with 3rd speed selector gear. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Inserting spring in selector gear The bent end of the spring -arrow- must be hooked into the hole in the selector gear.

Checking 3rd and 4th gear 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 the measured values and divide by 3. The determined value should not exceed 0.45 mm.

Installation position of circlips t  The circlips -1- and -2- secure the input shaft ball bearing → Chapter „Adjusting input shaft“. t  The circlip -3- secures the 3rd and 4th gear synchronising hub. Thickness: 2.00 mm. Identification: brown colour. t  The circlip -4- secures the 3rd and 4th gear synchronising hub. Determine thickness ⇒ table on → . Identification: blue colour. t  The circlip -5- secures the 5th gear wheel. Determine thickness ⇒ table on → .

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it. –  Determine circlip as accurately as possible from table. For Part Nos. refer to → Electronic parts catalogue. The following circlips are available for 3rd and 4th gear synchronising hub

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99	2.05

The following circlips are available for 5th gear wheel

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99

Pressing on 3rd and 4th gear synchronising hub t  Installation position: Higher inside collar faces 3rd gear.

Installation position of locking collar up to 05.03 Different types of locking collar are installed: version -A- with chamfered surface -arrow 1- or version -B- with large shoulder -arrow 3-. t  Installation position: Chamfered surface -arrow 1- faces towards 4th gear. Small shoulder -arrow 2- faces towards 3rd gear. Large shoulder -arrow 3- faces towards 4th gear.

Installation position of locking collar from 05.03 onwards Groove -arrow- faces towards 3rd speed selector gear.

Pressing on 5th gear wheel   WARNING Wear protective gloves. –  Heat 5th gear wheel to approx. 100 °C before pressing on. t  Installation position: High collar faces towards reverse gear.