Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust plate -VW 401-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Press tool -VW 412-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Drift sleeve -30-100-

t	Installing ring -2003/3-

t	Tube -2010-

t	Thrust plate -3005-

t	Guide sleeve -3039-

t	Press tool -40-21-

t	Thrust pad -3062-

t	Tube -3118-

t	Drift -3138-

t	Hot air blower -V.A.G 1416-

t	-3-Splitter -Kukko 17/2-

Pinion shaft - exploded view of components

t	Observe the general repair instructions → Chapter.

t	When installing new gears → Chapter „Code letters, allocation, transmission ratios, capacities“.

t	Adjustment is required if pinion shaft, bearing plate or tapered roller bearings are being renewed → Anchor.

1 -	Gearbox housing

q	Servicing → Chapter

2 -

Shim “S3”

q	Table of adjustments → Anchor

3 -	Large tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig. and → Fig.

4 -	Pinion shaft

q	Is mated with crown wheel (final drive gear set), always renew together as a set

q	Select correct version according to code letters → Parts catalogue

5 -	Large tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

6 -	4th gear wheel

q	Pressing off → Fig.

q	Pressing on → Fig.

7 -	Spacer sleeve

8 -	3rd gear wheel

q	Pressing off together with → Item → Fig.

q	Pressing on → Fig.

9 -	Inner race for 2nd speed selector gear

q	Pressing off together with → Item → Fig.

q	Pressing on → Fig.

10 -	Needle bearing for 2nd speed selector gear

q	Lubricate with gear oil before installing

11 -	2nd speed selector gear

q	Pressing off → Fig.

q	Before installing, fit spring and slide needle bearing onto pinion shaft

q	After installing, check axial clearance with a feeler gauge (0.15 ...  0.35 mm)

12 -	Synchro-ring for 2nd gear

q	With molybdenum coating

q	Checking for wear → Fig.

13 -	Synchronising hub for 1st and 2nd gear

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Installation position: flush hub towards 2nd speed selector gear

14 -	Locking collar for 1st and 2nd gear

q	Installation position: groove for selector fork faces towards 1st speed selector gear

15 -	Synchro-ring for 1st gear

q	Checking for wear → Fig.

16 -	Inner race for 1st speed selector gear

q	Pressing off → Fig.

q	Pressing on → Fig.

17 -	Needle bearing for 1st speed selector gear

q	Lubricate with gear oil before installing

18 -	1st speed selector gear

q	Before installing, insert spring → Fig.

q	After pressing on → Item, check axial clearance with a feeler gauge (0.15 ... 0.50 mm)

19 -	Small tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

20 -	Small tapered roller bearing outer race

q	Driving out → Fig.

q	Pressing in → Fig.

21 -

Shim “S4”

q	Table of adjustments →

22 -	Bearing plate

q	Servicing → Chapter

23 -

Circlip

q	Re-determining thickness → Anchor

24 -	6th gear wheel

q	Pressing off → Anchor

q	Pressing on → Anchor

q	Installation position: shoulder towards inner race for small tapered roller bearing

25 -

Circlip

q	Re-determining thickness → Anchor

26 -	5th gear wheel

q	Pulling off → Anchor

q	Driving on → Anchor

27 -

Circlip

28 -

End cover

q	Servicing → Chapter

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 three measured values together and divide by three. l  The average gap must not be less than 0.5 mm.

Checking synchro-ring with molybdenum coating for wear   Note Friction surface of intact synchro-ring has a graphite-grey, slightly porous appearance. –  Clean synchro-ring and make sure that friction surface is free of oil. If very shiny areas -A- have formed on friction surface or if brass-coloured surface underneath is already visible: –  Renew synchro-ring.

Pulling out outer race for large tapered roller bearing l  Stepped side of thrust pad -3062- rests against the outer race

Heating gearbox housing in order to fit tapered roller bearing outer race –  Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 °C, with a hot air blower.   WARNING Wear protective gloves.

Installing outer race for large tapered roller bearing in gearbox housing and pressing home –  Insert outer race only after heating gearbox housing and press home under workshop press for 1 ... 2 minutes until heat exchange has taken place.   WARNING Wear protective gloves.

Pressing off inner race of small tapered roller bearing for pinion shaft together with 1st speed selector gear A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pressing off 2nd speed selector gear with locking collar/synchronising hub for 1st and 2nd gear and inner race for 1st speed selector gear A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pressing off 3rd gear wheel together with inner race for 2nd speed selector gear A -  Splitter 22 ... 115 mm -Kukko 17/2-

Pressing off 4th gear wheel A -  Splitter 22 ... 115 mm -Kukko 17/2-   Note The 4th gear wheel can also be pressed off together with the 3rd gear wheel and the inner race for the 3rd speed selector gear.

Pressing off inner race for large tapered roller bearing A -  Splitter 22 ... 115 mm -Kukko 17/2-   Note Bearing is destroyed when pressing off.

Pressing on inner race for large tapered roller bearing –  Heat inner race to approx. 100 °C and fit.   WARNING Wear protective gloves. –  Press home ensuring there is no axial play.

Pressing on 4th gear wheel –  Heat gear to about 100 °C, fit and press home. l  Installation position: shoulder towards 3rd gear wheel.   WARNING Wear protective gloves.

Pressing on 3rd gear wheel –  Insert spacer sleeve -arrow-. –  Heat gear to about 100 °C, fit and press home. l  Installation position: shoulder towards 4th gear wheel   WARNING Wear protective gloves.

Pressing on inner race for 2nd speed selector gear –  Heat inner race to approx. 100 °C and fit.   WARNING Wear protective gloves. –  Press home ensuring there is no axial play.

Fitting 2nd speed selector gear, pressing on synchronising hub for 1st and 2nd gear –  Lubricate needle bearing with oil. –  Heat synchronising hub to approx. 100 °C and fit. l  Installation position: flush hub towards 2nd speed selector gear   WARNING Wear protective gloves. –  Press home ensuring there is no axial play.

Pressing on inner race for 1st speed selector gear –  Heat inner race to approx. 100 °C and fit.   WARNING Wear protective gloves. –  Press home ensuring there is no axial play.

Pressing on small tapered roller bearing inner race for pinion shaft –  Lubricate needle bearing with oil. –  Fit needle bearing, selector gear (with spring) and synchro-ring for 1st gear. –  Heat inner race to approx. 100 °C and fit.   WARNING Wear protective gloves. –  Press home ensuring there is no axial play.

Driving out outer race for small tapered roller bearing

Pressing in outer race for small tapered roller bearing –  Insert shim “S4” into bearing plate behind bearing seat. –  Press in small tapered roller bearing outer race as far as stop.