Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft   Note Removing and installing 3rd to 6th speed selector gears is described in → Chapter „Assembly sequence - dismantling and assembling gearbox“. Special tools and workshop equipment required t  Depth gauge

Detaching needle roller bearing from input shaft and fitting needle roller bearing onto input shaft Detaching needle roller bearing: –  Bend open needle roller bearing at separating point -arrow B- just far enough for it to be detached from input shaft (do not bend open more than necessary). Fitting needle roller bearing: l  The shoulder -arrow A- faces towards splines for 2nd gear. –  Bend open needle roller bearing at separating point -arrow B- just far enough for it to be guided over the input shaft and onto its seat -arrow C-.

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. l  The determined value should not exceed 0.45 mm.

Installation position of circlips t  The circlips -1- and -2- secure the input shaft ball bearing. Determining thickness → Chapter. t  The circlip -3- secures the needle bearing for 3rd speed selector gear and the 3rd and 4th gear synchro-hub. Thickness: 2.00 mm. t  The circlip -4- secures the 3rd and 4th gear synchro-hub. Determining thickness → Fig..

Determining thickness of circlip for synchro-hub for 3rd and 4th gear l  Synchro-hub is pressed on as far as stop. –  Determine the thickest circlip that will just fit and install it. For part number refer to → Electronic parts catalogue. The following circlips are available:

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99	2.05