Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft up to 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 type of synchromesh for 1st and 2nd gear as well as for 5th and reverse gear is fitted. Dismantling and assembling pinion shaft from 05.03 → Chapter.

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

Renew

q	Will be damaged during removal

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 -

Spring

q	Insert in 1st speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

10 -	Synchro-ring for 1st gear

q	Checking for wear → Fig.

11 -	Synchronising hub for 1st and 2nd gear

q	Pressing off → Fig.

q	Pressing on → Fig.

12 -

Circlip

q

Mark

q	Installation position → Fig.

q	Redetermine thickness if synchronising hub is replaced → Fig.

13 -	Needle bearing for 2nd gear

14 -	Locking collar for 1st and 2nd gear

q	Installation position → Fig.

15 -	Synchro-ring for 2nd gear

q	Checking for wear → Fig.

16 -

Spring

q	Insert in 2nd speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

17 -	2nd speed selector gear

18 -

Circlip

q

Mark

q	Installation position → Fig.

19 -	3rd gear wheel

q	Pressing off → Fig.

q	Groove faces 4th gear

q	Pressing on → Fig.

20 -

Circlip

q

Mark

q	Installation position → Fig.

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

21 -	4th gear wheel

q	Pressing off → Fig.

q	Shoulder faces towards 3rd gear

q	Pressing on → Fig.

22 -

Circlip

q

Mark

q	Installation position → Fig.

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

23 -	Needle bearing

24 -	5th speed selector gear

25 -

Spring

q	Insert in 5th speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

26 -	Synchro-ring for 5th gear

q	Checking for wear → Fig.

27 -

Circlip

q

Mark

q	Installation position → Fig.

28 -	5th gear and reverse gear synchronising hub

q	Pressing off → Fig.

q	Pressing on → Fig.

29 -

Circlip

q

Mark

q	Installation position → Fig.

q	Redetermine thickness if synchronising hub is replaced → Fig.

30 -	Needle bearing

q	For reverse gear

31 -	Locking collar for 5th and reverse gear

q	Installation position → Fig.

32 -	Synchro-ring for reverse gear

q	Checking for wear → Fig.

33 -

Spring

q	Insert in reverse selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

34 -	Reverse selector gear

35 -	Inner race for small tapered roller bearing 1)

q	Pressing off → Fig.

q	Pressing on → Fig.

36 -

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

37 -	Outer race for small tapered roller bearing 1)

q	Pulling out → Fig.

q	Pressing in → Fig.

38 -

Shim “S4”

q	Table of adjustments → Chapter

39 -	Pressure plate

q	Different thicknesses for aluminium and magnesium gearboxes → Fig.

40 -	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

41 -	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

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 towards the 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. –  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

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

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 the measured values and divide by 3. The determined value should not exceed 0.5 mm.

Pressing on 1st and 2nd gear synchronising hub t  Installation position: Higher inside collar faces 2nd gear.

Installation position of locking collar for 1st and 2nd gear t  Installation position: Chamfered surface -arrow 1- faces towards 2nd gear. Shoulder -arrow 2- faces towards 1st gear.

Pressing on 3rd gear wheel t  Installation position: Groove on gear wheel faces towards 4th gear.

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

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 Different types of locking collar are installed: version -A- with chamfered surface -arrow 1- or version -B- with large shoulder -arrow 3-. t  Make sure locking collar is correct version for reverse gear wheel → Fig. t  Installation position: Chamfered surface -arrow 1- faces towards reverse gear. Small shoulder -arrow 2- faces towards 5th gear. Large shoulder -arrow 3- faces towards reverse gear.

Pressing on inner race for small tapered roller bearing

Selecting correct locking collar for reverse gear wheel

A	Reverse gear wheel with chamfered surface	Both types of locking collar can be installed (with chamfered surface or with large shoulder)
B	Reverse gear wheel without chamfered surface	Install only locking collar with large shoulder; do not use locking collar with chamfered edge

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