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Dismantling and assembling pinion shaft and hollow shaft > < Servicing selector shaft with selector cylinder

A4 Mk2

Dismantling and assembling input shaft
   
Dismantling and assembling input shaft
Special tools and workshop equipment required
t  Thrust plate -VW 401-
t  Press tool -VW 412-
t  Tube -VW 519-
t  Feeler gauge

   
Exploded view
  Note
When installing new gears → Chapter „Code letters, allocation, transmission ratios, capacities“.
1 - Gearbox housing
q   Servicing → Chapter
2 - Needle bearing
q   For input shaft
q   Pulling out → Fig.
q   Driving in → Fig.
3 - Circlip
q   For needle bearing
4 - Circlip
q   For input shaft
5 - Thrust washer
6 - Needle bearing for 4th gear
q   Mark before removing
q   Do not interchange with needle bearing for 3rd gear
q   Lubricate with gear oil before installing
7 - 4th speed selector gear
q   Insert spring before installing → Fig.
q   After installing, check axial clearance with a feeler gauge (0.15 ...  0.35 mm)
8 - Synchro-ring for 4th gear
q   Checking for wear → Fig.
9 - Locking collar
q   Is paired with synchronising hub
q   Mark before removing → Anchor
10 - Circlip
q   Redetermine thickness if synchronising hub is being renewed → Fig.
q   Installation position: ends coincide with groove in synchronising hub
11 - Synchronising hub for 3rd and 4th gear
q   Pressing off → Fig.
q   Installation position: → Fig.
q   Pressing on → Fig.
12 - Synchro-ring for 3rd gear
q   With molybdenum coating
q   Checking for wear → Fig.
13 - 3rd speed selector gear
q   Insert spring before installing → Fig.
q   After pressing on → Item, check axial clearance with a feeler gauge (0.15 ... 0.35 mm)
14 - Needle bearing for 3rd gear
q   Mark before removing
q   Do not interchange with needle bearing for 4th gear
q   Lubricate with gear oil before installing
15 - Input shaft
16 - Spring pin
q   Drive in when renewing input shaft → Fig.
17 - Roller bearing
q   For input shaft
q   Pressing out and pressing in → Fig.
18 - Intermediate housing
q   Servicing → Chapter
19 - Inner race for roller bearing
q   Remove and fit by hand
20 - Circlip
21 - Thrust washer for needle bearing for 6th gear
q   Installation position: shoulder towards circlip, smooth contact surface towards needle bearing → Anchor
22 - Needle bearing for 6th gear
q   Lubricate with gear oil before installing
23 - 6th speed selector gear
q   Insert spring before installing → Fig.
q   After installing, check axial clearance with a feeler gauge (0.15 ...  0.35 mm)
24 - Synchro-ring for 6th gear
q   Checking for wear → Fig.
25 - Synchronising hub for 5th and 6th gear
q   Pulling off → Anchor
q   Driving on → Anchor
q   Installation position: projecting centre hub towards 5th speed selector gear
26 - Locking collar
q   Is paired with synchronising hub
q   Mark before removing → Anchor
27 - Synchro-ring for 5th gear
q   Checking for wear → Fig.
28 - 5th speed selector gear
q   Insert spring before installing → Fig.
q   After installing, check axial clearance → Anchor
29 - Inner race for 5th speed selector gear
q   Pulling off → Anchor
q   Driving on → Anchor
30 - Needle bearing for 5th gear
q   Lubricate with gear oil before installing
31 - 1st inner race for input shaft ball bearing
q   Pulling off → Anchor
q   Driving on → Anchor
32 - End cover
q   Servicing → Chapter
33 - 2nd inner race for ball bearing for input shaft
q   Pulling off → Anchor
q   Driving on → Anchor
34 - Multi-point socket head bolt, 150 Nm
q   Loosening and tightening → Anchor

   
Inserting spring in selector gear
–  Insert spring -arrow- in selector gear and hook bent end in hole.
  V35-1343
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 3 measured values together and divide by 3.
l  The average gap must not be less than 0.5 mm.
  V35-1342
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.
  A35-0049
Determining thickness of circlip
l  Synchronising hub pressed on as far as stop. Note installation position when pressing on → Fig..
–  Determine the thickest circlip that can still just be fitted.
l  The opening of circlip must align with groove in synchronising hub.
–  Select required circlip thickness from following table:
  V35-1347
Available circlips - Thickness in mm 1)
1.901.962.02
1.931.992.05
l  1) For Part Nos. refer to → Electronic parts catalogue.

–  Fit circlip.
   
Pressing off 3rd and 4th gear synchronising hub
  V35-1344
Installation position of synchronising hub
l  Oil groove in synchronising hub -arrow 1- must coincide with oil drilling -arrow 2- in input shaft.
  V35-1348
Pressing on synchronising hub for 3rd and 4th gear
  WARNING
Wear protective gloves.
–  Heat synchronising hub to approx. 100 °C, fit in position and press home.
–  Determine circlip and fit → Fig..
  V35-1345
Driving spring pin into input shaft
–  Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B- in until it touches drift.
  V35-1349

Dismantling and assembling pinion shaft and hollow shaft > < Servicing selector shaft with selector cylinder