Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft and hollow shaft

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 411-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Tube -VW 416 B-

t	Tube -VW 418 A-

t	Thrust ring -VW 429-

t	Thrust plate -VW 447 i-

t	Press tool -VW 454-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Support -40 - 103-

t	Tube -2010-

t	Thrust pad -3062-

t	Fitting tool -3128-

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

t	-3-Splitter -Kukko 17/2-

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.

1 -	Gearbox housing 1)

2 -

Shim “S3”

q	Table of adjustments → Chapter

3 -	Double tapered roller bearing outer race 1)

q	Renew together with → Item

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 -	Double tapered roller bearing inner race 1)

q

Renew

q	Will be damaged during removal

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -

Circlip

q	Redetermine thickness if double tapered roller bearing is renewed → Fig.

7 -	Needle bearing

q	For pinion shaft in hollow shaft

q	Lubricate with MoS2 grease

8 -	Hollow shaft 1)

9 -	Needle bearing for 1st gear

10 -	Needle bearing for 1st gear

11 -	1st speed selector gear

12 -

Spring

q	Insert in 1st speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

13 -	Synchro-ring for 1st gear

q	Checking for wear → Fig.

14 -	Synchronising hub for 1st and 2nd gear

q	Pressing off → Fig.

q	Pressing on → 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 -	Locking collar for 1st and 2nd gear

q	Installation position → Fig.

18 -	Synchro-ring for 2nd gear

q	Checking for wear → Fig.

19 -

Spring

q	Insert in 2nd speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

20 -	2nd speed selector gear

21 -

Circlip

q

Mark

q	Installation position → Fig.

22 -	3rd gear wheel

q	Pressing off → Fig.

q	Pressing on → Fig.

23 -

Circlip

q

Mark

q	Installation position → Fig.

q	If the 3rd gear wheel is renewed determine thickness of required new circlip → Fig.

24 -	4th gear wheel

q	Pressing off → Fig.

q	Pressing on → Fig.

25 -

Circlip

q

Mark

q	Installation position → Fig.

q	If the 4th gear wheel is renewed determine thickness of required new circlip → Fig.

26 -	Needle bearing

27 -	5th speed selector gear

28 -

Spring

q	Insert in 5th speed selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

29 -	Synchro-ring for 5th gear

q	Checking for wear → Fig.

30 -

Circlip

q

Mark

q	Installation position → Fig.

31 -	5th gear and reverse gear synchronising hub

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 -	5th and reverse gear locking collar

q	Installation position → Fig.

35 -	Synchro-ring for reverse gear

q	Checking for wear → Fig.

36 -

Spring

q	Insert in reverse selector gear → Fig.

q	Allocation to selector gear → Electronic parts catalogue

37 -	Reverse selector gear

38 -

Circlip

q

Mark

q	Installation position → Fig.

39 -	Tapered roller bearing inner race 1)

q	Pressing off → Fig.

q	Pressing on → Fig.

40 -

Bush

q	Secures outer race for small tapered roller bearing

q	Pulling out → Fig.

q	Need not be fitted after the small tapered roller bearing has been renewed

41 -	Tapered roller bearing outer race 1)

q	Pressing out → Fig.

q	Pressing in → Fig.

42 -

Shim “S4”

q	Table of adjustments → Chapter

43 -

Ring

q	For rubber washer

q	For correct version, refer to → Electronic parts catalogue

44 -	Rubber washer

q	Compensates length variations

q	For correct version, refer to → Electronic parts catalogue

45 -	Gearbox cover

Pulling out double tapered roller bearing outer race –  Remove differential → Chapter. –  Place thrust piece of fitting tool -3128- below the outer race. –  Attach threaded part of fitting tool -3128- with thrust plate -VW 401- onto gearbox housing. The outer race will be pulled out of the housing when the bolt is tightened.

Pressing off double tapered roller bearing inner race –  Remove circlip before pressing off. –  The outer race -A- must be fitted to press off the inner race.   Note The double tapered roller bearing inner race will be destroyed when it is pressed off.

Pressing in double tapered roller bearing outer race Smaller diameter of thrust pad -3062- faces outer race.

Pressing on double tapered roller bearing inner race

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

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

Pressing out tapered roller bearing outer race –  The outer race is pressed out together with the ring → Item, shim “S4” → Item and the rubber washer for compensating length variations → Item.

Pressing in tapered roller bearing outer race

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

Pressing on tapered roller bearing inner race –  Fit circlip before pressing on inner race.

Pressing off 5th gear and reverse gear synchronising 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 off 3rd gear wheel 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 off synchronising hub with 1st speed selector gear.

Installation position of circlips –  The required circlips for the synchronising hubs, needle bearings and individual gear wheels should be selected as shown in → Fig.. t  Circlip -1- secures the 1st and 2nd gear synchronising hub. Identification: blue colour.

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99

t  Circlip -2- secures the needle bearing/ 2nd speed selector gear. Identification: blue colour.

Circlip thickness (mm)

2.50

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

Circlip thickness (mm)
1.90	1.98	2.06
1.94	2.02

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

Circlip thickness (mm)
1.86	1.94
1.90	1.98

t  Circlip -5- secures the needle bearing/ 5th speed selector gear. Identification: brown colour.

Circlip thickness (mm)

2.00

t  Circlip -6- secures the synchronising hub for 5th and reverse gear. Identification: blue colour.

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99	2.05

t  Circlip -7- secures needle bearing for reverse selector gear.

Circlip thickness (mm)

2.50

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

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 -E- into locking collar and measure gap -a- at positions -A-, -B- and -C- using depth gauge -D-. –  Add the measured values and divide by 3. The determined value should not exceed 0.45 mm.

Pressing on 1st and 2nd gear synchronising hub t  Installation position: High inside collar faces towards 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: High inside collar faces towards 3rd gear.

Pressing on 5th gear and reverse gear synchronising hub t  Installation position: High inside collar faces towards 5th gear.

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.

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