Audi Workshop Service and Repair Manuals

Pulling spur gear off crankshaft and shrink-fitting new spur gear

t  Hotplate (commercially available)

t  Fitting tool -10 - 203-

t  Puller -T10392- t  Thrust piece -T10392/1- t  Temperature gauge-VAS 6519- –  Remove front sealing flange → Chapter. –  Remove sump → Chapter.   Note It is sufficient to detach idler gear if balance shaft assembly does not need to be renewed. –  Remove balance shaft assembly → Chapter. Pulling off spur gear

–  Insert thrust piece -T10392/1- in end of crankshaft.

–  Insert puller -T10392- in holes in spur gear, turn clockwise -arrow- and screw in locking pins -A-.

–  Counterhold crankshaft with ring spanner -A- and pull spur gear off end of crankshaft by screwing in spindle with ring spanner -B-. Shrink-fitting spur gear   Note t  While heating up the new spur gear, monitor the temperature with the temperature gauge -VAS 6519-. t  When the temperature reaches 200°C, you have approx. 4 seconds to fit the spur gear on the crankshaft. t  A higher temperature increases the amount of time available (220°C = approx. 6 seconds). t  Make sure the end of the crankshaft is clean.   Caution Do not exceed a maximum temperature of 240°C; otherwise the spur gear can become discoloured and distorted.

–  Place the new spur gear flat on a commercially available hotplate and heat it up to at least 200°C, but not more than 240°C. The lettering must face upwards. –  Set temperature gauge -VAS 6519- to measuring range 2. –  Position temperature sensor -VAS 6519/1- on collar of spur gear (as shown) and read off temperature at temperature gauge.   WARNING Risk of burns. Use suitable protective gloves for the following steps.

–  When the required temperature has been reached, pick up the spur gear with pliers as illustrated.   Note Take care not to damage the teeth of the spur gear.

–  With the aid of fitting tool -10 - 203-, slide spur gear by hand onto end of crankshaft as far as stop. This must be done without delay, taking care to keep the gear straight. –  Wait a few minutes to allow the spur gear to cool down, and then install the balance shaft assembly. → Chapter „Installing a new balance shaft assembly“ → Chapter „Re-installing the "old" balance shaft assembly“