Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft - assembly sequence

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Drift sleeve -30 - 100-

t	Tube -32 - 109-

t	Drift sleeve -40 - 21-

t	Tube -2040-

t	Guide sleeve -3039-

t	Tube for wheel bearing -3345-

t	Thrust plate -T10084 A-

t	Feeler gauge

t  Clamping device -T10306-

t  Angled ring spanner -T10307- Dismantling input shaft –  First remove circlip → Item and washer → Item in front of 12-point nut on removed input shaft.

–  Apply angled ring spanner -T10307- to 12-point nut. –  For the next step, the end of the input shaft with the clutch plate splines must be placed in clamping device -T10306- and clamped in a vice. A -  Torque wrench   Note t  Due to the offset centre of gravity of the input shaft, the input shaft must be supported (e.g. by a second mechanic). t  The 12-point nut has a “left-hand thread” (turn tool clockwise to unfasten nut). –  Unfasten twelve-point nut by turning in direction of -arrow-. –  Remove 4th speed selector gear with needle bearing and synchro-rings.

–  Press off 3rd speed, 5th speed and 6th speed selector gears together with synchronising hub and needle bearing inner races.   Note It may be necessary to exert a pressure of up to 200 kN (20 t).

–  Position bearing mounting -A- over input shaft roller bearing to prevent the rollers from being pressed out of the bearing cage. –  Press roller bearing off input shaft. –  Clean thread for 12-point nut on input shaft to remove any residue of locking fluid. Assembling input shaft   Note t  Clean the input shaft thread. t  Lubricate all needle bearings and synchro-rings with gear oil before fitting. t  Heat needle bearing inner races to 130 °C (max.) before pressing on (wear protective gloves). t  Heat synchronising hubs to 100 °C (max.) before pressing on (wear protective gloves). t  Always press on roller bearing, needle bearing inner races and synchronising hubs as far as stop to make sure the axial clearance of the selector gears meets the specification.

Checking 3rd to 6th gear synchro-rings for wear –  Check outer friction surface on inner ring for scoring or visible traces of wear and renew if necessary. –  Check inner friction surface of synchro-ring for scoring or visible traces of wear and renew if necessary. –  Fit inner ring, intermediate ring and synchro-ring onto cone of selector gear and rotate to achieve proper seating.   Note To achieve proper seating, rotate synchro-rings approx. one turn while pressing down rings simultaneously. –  Then measure gap -a- using a feeler gauge.

Gap -a-	Wear limit
3rd to 6th gear	0.7 mm

Note Renew inner ring, intermediate ring and synchro-ring for the corresponding gear together.

Installation position of synchro-rings for 3rd to 6th gear   Note If components are not being renewed, make sure they are re-installed on the same gear. –  Fit inner ring -2- onto selector gear -1-. –  Fit intermediate ring -3-. Lug -B- must be inserted into recess -A-. –  Fit synchro-ring -4-. Guide lugs -C- through recess -arrow-.

–  Press roller bearing onto input shaft as far as stop (shoulder on tube -VW 415 A- faces roller bearing). –  Install 5th speed selector gear with needle bearing and synchro-rings. Now fit PTFE element if the input shaft is supplied with additional “PTFE element” → Fig..

Assembling 5th and 6th gear locking collar/synchronising hub –  Slide locking collar -1- over synchronising hub -2-. l  The groove -arrow A- on the locking collar and the high inside collar -arrow B- on the synchronising hub must face 5th speed selector gear. l  The recesses -arrow C- for the thrust blocks -3- in the synchronising hub must align with the recesses -arrow D- in the locking collar. –  Then position thrust blocks -3- in synchronising hub and press thrust blocks into recesses in locking collar.

Pressing on 5th and 6th gear synchronising hub with locking collar Note the following when performing the following steps: l  Installation position of synchronising hub: high inside collar faces 5th speed selector gear –  Fit input shaft in drilling of thrust plate -VW 401-. –  Position drift sleeves on centre of heated components (synchronising hub and needle bearing inner races). –  First press on components just briefly, then stop exerting pressure and check whether drift sleeves are still positioned properly and press on as far as stop. l  On an input shaft with “PTFE element”, the “PTFE element” must be fitted before pressing on the synchronising hub for 5th and 6th gear. l  When pressing on, lugs on synchro-ring -arrow 1- must line up with recesses in synchronising hub -arrow 2-.

Pressing on needle bearing inner race -A- for 6th speed selector gear

–  Install 6th speed selector gear -A- with needle bearing and synchro-rings. –  Position thrust washer -B- for 3rd speed and 6th speed selector gears on 6th speed selector gear.

Pressing on needle bearing inner race -A- for 3rd speed selector gear –  Fit 3rd speed selector gear with needle bearing and synchro-rings.

Installation position of 3rd and 4th gear synchronising hub l  The shoulder -arrow- on the synchronising hub faces towards 3rd speed selector gear.

Pressing on synchronising hub for 3rd and 4th gear l  Note installation position of synchronising hub → Fig. l  When pressing on, lugs on synchro-rings must line up with recesses in synchronising hub.

Installation position of 3rd and 4th gear locking collar l  The groove -arrow- on the locking collar faces towards 3rd speed selector gear.

Assembling 3rd and and 4th gear locking collar/synchronising hub l  3rd and 4th gear synchronising hub is pressed on. –  Apply a small amount of grease to convex side -arrow 1- of each of the three locking pieces -A-. –  Fit the three locking pieces with convex side first into recesses in locking collar -B-. l  Note installation position of locking collar → Fig.. –  Then position locking collar over synchronising hub -C- so that recesses on synchronising hub -arrow 2- align with locking pieces. –  Then position thrust blocks -D- in synchronising hub and press thrust blocks in direction of -arrow 3- into recesses in locking collar. The locking collar must be held in the centre position.

Pressing on needle bearing inner race for 4th speed selector gear –  Fit 4th speed selector gear with needle bearing and synchro-rings. –  Clean thread of used 12-point nut. –  Screw 12-point nut hand-tight onto input shaft.

–  Apply angled ring spanner -T10307- to 12-point nut. –  For the next step, the end of the input shaft with the clutch plate splines must be placed in clamping device -T10306- and clamped in a vice.   Note t  Due to the offset centre of gravity of the input shaft, the input shaft must be supported (e.g. by a second mechanic). t  The 12-point nut has a “left-hand thread” (turn tool anti-clockwise to fasten nut). A -  Torque wrench –  Turn 12-point nut in direction of -arrow- and tighten to 75 Nm. –  Then check selector gears for freedom of movement and axial play. l  The axial play of the selector gears must be at least 0.10 mm.

The thickness of the circlip -1- and the shim -2- is determined according to the following procedure: –  The gap after fitting shim and circlip available as spare parts must be max. 0.10 mm (measured between circlip and shim). –  Check the gap with a feeler gauge -3-.   Note The circlip -1- must be properly seated in the base of the groove when checking the gap. –  Determine shim and circlip from table. Part numbers → Electronic parts catalogue “ETKA”. The following circlips are available:

Circlip thickness (mm)
1.70	1.80	1.90
1.75	1.85

The following shims are available:

Shim thickness (mm)
0.9	1.1	1.3
1.0	1.2

–  Install shim and circlip of the correct thickness as determined above.