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Dismantling and assembling pinion shaft > < Pinion shaft

A4 Mk2

Pinion shaft - exploded view of components
   
Pinion shaft - exploded view of components
Dismantling and assembling pinion shaft → Chapter
  Note
t  Refer to technical data when installing new gears or final drive gear set → 6-speed manual gearbox 0A2, front-wheel drive; Rep. Gr.00.
t  Always renew the double angular contact ball bearing on the pinion shaft when renewing the final drive gear set or if gear oil is contaminated with metal particles.
t  Lubricate all needle bearings and synchro-rings with gear oil before installing.
t  When renewing synchro-rings, renew inner ring, intermediate ring and synchro-ring for the corresponding gear together.
t  If synchro-rings are not being renewed, make sure they are re-installed on the same gear. Do not interchange synchro-rings for reverse gear with synchro-rings for 1st and 2nd gear → Fig..
t  Items 18 to 25 and 28 were modified on 1st and 2nd gear selector rod version with spring-loaded selector fork → Fig.. Refer to → Electronic parts catalogue “(ETKA)” to allocate components.
t  Adjustment work is required when renewing the parts marked with 1). Table of adjustments → Chapter.
1 - Gearbox housing 1)
2 - Shim “S3”
q   Table of adjustments → Chapter
3 - Pinion shaft 1)
q   Is mated with crown wheel, always renew together as a set
q   Dismantling and assembling → Chapter
q   Adjusting crown wheel and pinion shaft → Chapter
4 - Double angular contact ball bearing
q   If only this bearing is renewed, re-adjustment is not necessary
q   Pressing off → Fig.
q   Pressing on → Fig.
q   Installation position: shoulder on outer race faces towards pinion gear
5 - Shim “S4”
q   Table of adjustments → Chapter
6 - Retaining plate
q   Installation position: machined side faces towards gearbox housing (can only be installed in one position).
7 - Bolt, 30 Nm
q   6 x
q   Apply locking fluid -AMV 185 101 A1- when fitting
8 - Shim “S5”
q   To position 4th speed gear
q   Re-determining thickness → Chapter
9 - 4th gear wheel
q   Pulling off → Fig.
q   Driving on → Fig.
q   Installation position: high inside collar faces 3rd gear wheel
10 - 3rd gear wheel
q   Pulling off → Fig.
q   Driving on → Fig.
q   Installation position: high inside collar faces 4th gear wheel
11 - 6th gear wheel
q   Pulling off → Fig.
q   Driving on → Fig.
q   Installation position: high inside collar faces 5th gear wheel
12 - 5th gear wheel
q   Pulling off → Fig.
q   Driving on → Fig.
q   Installation position: high inside collar faces towards 6th gear wheel
13 - Roller bearing
q   For pinion shaft
q   Do not interchange with roller bearing for input shaft
q   Pulling off with 5th gear wheel → Fig.
q   Driving on → Fig.
14 - Bearing mounting
q   The roller bearing outer race → Item cannot be renewed individually; renew bearing mounting if signs of wear are found.
q   The roller bearing outer race must not have any radial clearance in the bearing mounting.
15 - Shim “S6”
q   To position 2nd speed selector gear
q   Re-determining thickness → Chapter
16 - Needle bearing inner race
q   For 2nd speed selector gear
q   Pulling off with 5th gear wheel → Fig.
q   Driving on → Fig.
17 - Needle bearing
q   For 2nd gear
18 - 2nd speed selector gear
19 - Inner ring for 2nd gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
20 - Intermediate ring for 2nd gear
q   Installation position → Fig.
q   Checking for wear → Fig.
21 - Synchro-ring for 2nd gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
22 - Locking collar with synchronising hub for 1st and 2nd gear
q   Removing and installing → Chapter
q   Installation position of locking collar: the side with asymmetric splines must point towards 2nd gear → Anchor
q   Assembling locking collar/synchronising hub → Anchor
23 - Synchro-ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
24 - Intermediate ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
25 - Inner ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
26 - Needle bearing inner race
q   For 1st speed selector gear
q   Pull off together with 2nd speed selector gear → Fig.
q   Driving on → Fig.
27 - Needle bearing
q   For 1st gear
28 - 1st speed selector gear
29 - Thrust washer
q   For 1st speed selector gear and reverse gear
30 - Needle bearing inner race
q   For reverse selector gear
q   Pull off together with 1st speed selector gear → Fig.
q   Driving on → Fig.
31 - Needle bearing
q   For reverse gear
32 - Reverse selector gear
q   With locking collar for reverse gear
q   Removing and installing → Chapter
q   Dismantling and assembling locking collar and reverse selector gear → Fig.
33 - Synchro-ring for reverse gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Renew if scored or if there are visible traces of wear
34 - Intermediate ring for reverse gear
q   Installation position → Fig.
q   Checking for wear → Fig.
35 - Inner ring for reverse gear
q   Installation position → Fig.
q   Renew if scored or if there are visible traces of wear
36 - Clutch unit
q   Removing and installing → Chapter
37 - Washer
38 - Grooved ball bearing
q   Pull off with clutch unit → Fig.
q   Driving on → Fig.
39 - Nut, 300 Nm
q   Apply locking fluid -AMV 185 101 A1- when fitting
q   Slackening → Anchor
q   Tightening → Anchor
40 - Gearbox cover
41 - Thrust block
q   Installing thrust blocks (3x) → Fig.
42 - Reverse selector gear
43 - Locking collar for reverse selector gear

   

Dismantling and assembling pinion shaft > < Pinion shaft