Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft from 05.03

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 408 A-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Crankshaft seal installing tool -VW 204 B-

t	Tube -VW 421-

t	Installing sleeve -VW 455-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Tube -2010-

t	Thrust plate -3005-

t	Press tool -3118-

t	Fitting tool -3128-

t	Assembly tool -3301-

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

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

t	-3-Splitter -Kukko 17/2-

t

From 05.03 onwards, a new synchromesh mechanism was introduced with triple synchromesh on 1st gear and double synchromesh on 2nd gear as well as synchro-rings with larger friction cone and smaller dog teeth on 5th and reverse gear. The selector gears, locking collars and synchronising hubs are modified accordingly; these parts cannot be installed together with synchromesh components of the previous version.

t	Refer to technical data → Chapter when installing new gear wheels or the final drive gear set.

t	Adjustment work is required when renewing the parts marked with 1) → Chapter „Table of adjustments“.

1 -	Gearbox housing 1)

q	Housing manufactured from aluminium or magnesium → Item

2 -

Shim “S3”

q	Table of adjustments → Chapter

3 -	Outer race for large tapered roller bearing 1)

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Pinion shaft 1)

q	Is mated with crown wheel, always renew together as a set

q	Adjusting pinion shaft and crown wheel → Chapter

5 -	Inner race for large tapered roller bearing 1)

q	Will be damaged during removal

q

Renew

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -

Circlip

q

Mark

q	Installation position → Fig.

q	Re-determine thickness if tapered roller bearing is renewed → Fig.

7 -	Needle bearing for 1st gear

8 -	1st speed selector gear

9 -	Inner ring for 1st gear

q	Installation position → Fig.

q	Checking for wear → Fig.

q	Renew if scored or if there are visible traces of wear

10 -	Intermediate ring for 1st gear

q	Installation position → Fig.

q	Checking for wear → Fig.

11 -	Synchro-ring for 1st gear

q	Installation position → Fig.

q	Checking for wear → Fig.

q	Renew if scored or if there are visible traces of wear

12 -	Locking collar for 1st and 2nd gear

q	Mark installation position

q	Assembling locking collar/synchronising hub → Fig.

13 -	Locking piece

q	Installing locking pieces (3x) → Fig.

14 -	Synchronising hub for 1st and 2nd gear

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Assembling locking collar/synchronising hub → Fig.

15 -

Circlip

q

Mark

q	Installation position → Fig.

q	Redetermine thickness if synchronising hub is replaced → Fig.

16 -	Needle bearing for 2nd gear

17 -	Synchro-ring for 2nd gear

q	Installation position → Fig.

q	Checking for wear → Fig.

q	Renew if scored or if there are visible traces of wear

18 -	Intermediate ring for 2nd gear

q	Installation position → Fig.

q	Checking for wear → Fig.

19 -	Inner ring for 2nd gear

q	Installation position → Fig.

q	Checking for wear → Fig.

q	Renew if scored or if there are visible traces of wear

20 -	2nd speed selector gear

21 -

Circlip

q

Mark

q	Installation position → Fig.

22 -	3rd gear wheel

q	Pressing off → Fig.

q	Groove faces 4th gear

q	Pressing on → Fig.

23 -

Circlip

q

Mark

q	Installation position → Fig.

q	If the 3rd gear wheel is renewed redetermine thickness → Fig.

24 -	4th gear wheel

q	Pressing off → Fig.

q	Shoulder faces towards 3rd gear

q	Pressing on → Fig.

25 -

Circlip

q

Mark

q	Installation position → Fig.

q	If the 4th gear wheel is renewed redetermine thickness → Fig.

26 -	Needle bearing

27 -	5th speed selector gear

q	Distinctive feature of modification → Fig.

28 -

Spring

q	Distinctive feature of modification → Fig.

q	Insert in 5th speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

29 -	Synchro-ring for 5th gear

q	Distinctive feature of modification → Fig.

q	Checking for wear → Fig.

30 -

Circlip

q

Mark

q	Installation position → Fig.

31 -	5th gear and reverse gear synchronising hub

q	Distinctive feature of modification → Fig.

q	Pressing off → Fig.

q	Pressing on → Fig.

32 -

Circlip

q

Mark

q	Installation position → Fig.

q	Redetermine thickness if synchronising hub is replaced → Fig.

33 -	Needle bearing

q	For reverse gear

34 -	Locking collar for 5th and reverse gear

q	Distinctive feature of modification → Fig.

q	Installation position: groove faces towards 5th gear → Fig.

35 -	Synchro-ring for reverse gear

q	Distinctive feature of modification → Fig.

q	Checking for wear → Fig.

36 -

Spring

q	Distinctive feature of modification → Fig.

q	Insert in reverse selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

37 -	Reverse selector gear

q	Distinctive feature of modification → Fig.

38 -	Inner race for small tapered roller bearing 1)

q	Pressing off → Fig.

q	Pressing on → Fig.

39 -

Bush

q	Secures outer race for small tapered roller bearing

q	Pulling out → Fig.

q	Need not be refitted after the small taper roller bearing has been renewed

40 -	Outer race for small tapered roller bearing 1)

q	Pulling out → Fig.

q	Pressing in → Fig.

41 -

Shim “S4”

q	Table of adjustments → Chapter

42 -	Pressure plate

q	Different thicknesses for aluminium and magnesium gearboxes → Fig.

43 -	Rubber disc

q	Compensates length variations

q	To remove, screw self-tapping screw into centre of disc and use screw to pull out disc

q	Different thicknesses for aluminium and magnesium gearboxes → Fig.

q	Select correct version according to gearbox code letters → Electronic parts catalogue → Chapter

44 -	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

Modified 5th and reverse gear synchromesh from 05.03 onwards   Note Components of the previous version (up to 05.03) cannot be installed together with components of the new version (from 05.03 onwards). The following components were modified: 1 -  5th speed selector gear 2 -  Synchro-spring 3 -  Synchro-ring for 5th gear 4 -  Synchronising hub for 5th and reverse gear 5 -  Locking collar for 5th and reverse gear 6 -  Synchro-ring for reverse gear 7 -  Synchro-spring 8 -  Selector gear for reverse gear Modified components: t  Smaller dog teeth -arrows A- t  Synchro-rings with larger friction cone -arrows B-

Pulling out securing bush for outer race for small tapered roller bearing A -  Internal puller 12...14.5 mm, e.g. -Kukko 21/1-

Pulling out outer race for small tapered roller bearing –  Screw adapter -VW 771/40- into pressure plate. –  Attach multi-purpose tool -VW 771- and pull outer race out via the pressure plate.

Pressing in outer race for small tapered roller bearing

Pulling out outer race for large tapered roller bearing –  Removing differential → Chapter. –  Place thrust piece of fitting tool -3128- below the outer race. –  Fit threaded spindle and thrust pad of assembly tool -3301- with thrust plate -VW 401- onto gearbox housing. The outer race will be pulled out of the housing when the bolt is tightened.

Pressing in outer race for large tapered roller bearing The smaller diameter of the crankshaft seal installing tool -VW 204 B- faces outer race.

Pressing off inner race for small tapered roller bearing –  Press off inner race with reverse gear selector gear A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing off 5th gear and reverse gear synchro hub –  Remove circlip before pressing off. –  Press off synchronising hub with 5th speed selector gear A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing off 4th gear wheel –  Remove circlip before pressing off.

Pressing off 3rd gear wheel –  Remove circlip before pressing off.   Note When pressing off, make sure that only the gear teeth (driving teeth) of the selector gear -arrows- and not the dog teeth contact the splitter -A-. Otherwise the dog teeth will be damaged. –  Press 3rd gear wheel off with 2nd speed selector gear A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

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

Pressing off inner race for large tapered roller bearing –  Remove circlip before pressing off. –  The outer race -A- must be fitted to press off the inner race.

Pressing on inner race for large tapered roller bearing

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it. The circlips for the synchronising hubs and individual gear wheels should also be determined as shown for the taper roller bearing. For available circlips and part Nos. refer to → Electronic parts catalogue.

Installation position of circlips   Note Select correct circlips from → Electronic parts catalogue. –  The required circlips for the synchronising hubs, needle bearings and individual gear wheels should be selected as shown in → Fig.. t  Circlip -1- secures inner race for tapered roller bearing.

Circlip thickness (mm)
2.00	2.06	2.12
2.03	2.09	2.15

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

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99

t  Circlip -3- secures the needle bearing for 2nd speed selector gear. Identification: Colour - blue

Circlip thickness (mm)

2.50

t  Circlip -4- secures the 3rd gear wheel.

Circlip thickness (mm)
1.90	1.98	2.06
1.94	2.02

t  Circlip -5- secures the 4th gear wheel.

Circlip thickness (mm)
1.86	1.94
1.90	1.98

t  Circlip -6- secures the needle bearing for 5th speed selector gear. Identification: Colour - brown

Circlip thickness (mm)

2.00

t  Circlip -7- secures the synchronising hub for 5th and reverse gear. Identification: Colour - blue

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99	2.05

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-. l  Lug -B- must be inserted into recess -A-. –  Fit synchro-ring -4-. l  Guide lugs -C- through recess -arrow-.

Checking 1st gear inner ring for wear –  Press inner ring -1- onto tapered surface 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 synchro-ring for wear –  Press inner ring, intermediate ring and synchro-ring onto tapered surface 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.

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 splines of locking collar and synchronising hub -arrow B- coincide.

Pressing on 3rd gear wheel t  Installation position: Higher inside collar or groove on gear wheel faces towards 4th gear.

Pressing on 4th gear wheel t  Installation position: Higher inside collar or groove on gear wheel faces towards 3rd gear.

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

Checking 5th and reverse 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.

Pressing on 5th gear and reverse gear synchronising hub t  Installation position: Higher inside collar faces 5th gear.   Note The large internal diameter in tube -2010- faces towards synchronising hub.

Installation position of locking collar for 5th and reverse gear t  Installation position: Groove -arrow- faces towards 5th speed selector gear.

Pressing on inner race for small tapered roller bearing

Pressure plate identification

Gearbox housing	Distance -a-
Aluminium	14.8 or 15.3 mm
Magnesium → Chapter	10.7 mm

Identification of rubber discs

Gearbox housing	Distance -a-
Aluminium	7.0 mm
Magnesium	11.0 mm