Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft - assembly sequence

Special tools and workshop equipment required

t	Drift sleeve -VW 244 B-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Press tool -VW 434-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Press tool -40 - 21-

t	Support bridge -2011-

t	-3-Splitter -Kukko 17/2-

t	Inductive heater -VAS 6414-

t	Depth gauge

Dismantling input shaft l  Input shaft has been detached from output shaft and bearing mounting → Chapter. l  Bolt in input shaft has been loosened and removed → Anchor. l  If synchro-rings are not being renewed, make sure they are re-installed on the same gear. l  Do not confuse locking collar for 3rd/4th gear with locking collar for 5th/6th gear. Mark locking collars accordingly.

–  Press off 3rd speed, 4th speed and 6th speed selector gears together with synchro-hub for 3rd/4th gear and needle bearing inner races. –  Detach circlip for 5th /6th gear synchro-hub from input shaft.   Note Mark this circlip so that it is not interchanged with the circlip below the 5th /6th gear synchro-hub.

–  Press off locking collar with 5th/6th gear synchro-hub and 5th speed selector gear.

–  Open out needle bearing -2- for 5th gear and guide it carefully over circlip -1- and teeth -3- for 5th/6th gear synchro-hub.   Note t  The circlip -1- below teeth -3- for the 5th/6th gear synchro-hub should only be removed from the input shaft if the roller bearing is being renewed (next step). t  Always renew the circlip if it has been removed. –  Remove circlip -1-.

–  Press roller bearing off input shaft. A -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note t  The roller bearing will be damaged when it is pressed off and must therefore always be renewed. t  If the input shaft is being renewed, the roller bearing does not have to be pressed off the shaft. t  To press off the roller bearing, you can also break open the cage of the bearing using a screwdriver or similar and then apply the splitter to the inner race. –  Clean thread for multi-point socket head bolt in input shaft to remove any remaining locking fluid. Assembling input shaft   Note t  Lubricate all needle bearings and synchro-rings with gear oil before fitting. t  Checking synchro-rings for wear → Chapter. t  Note allocation of synchro-rings to locking collars → Chapter. t  Using inductive heater -VAS 6414- or similar, heat needle bearing inner races to 130 °C (max.) before pressing on (wear protective gloves). t  Using inductive heater -VAS 6414- or similar, heat synchro-hub to 100 °C (max.) before pressing on (wear protective gloves). t  Always press on roller bearing, needle bearing inner races and synchro-hubs as far as stop to make sure the axial clearance of the selector gears meets the specification.

Inserting synchro-spring in selector gear The bent end of the synchro-spring -arrow- must be hooked into the hole in the selector gear.

–  Press roller bearing onto input shaft as far as stop.

–  Open out needle bearing -2- for 5th speed selector gear and guide it carefully over splines for 5th/6th gear synchro-hub -3-; do not seat needle bearing on shoulder -arrow- of input shaft.   Note If the circlip -1- has not been removed, the needle bearing -2- must also be guided carefully over this circlip. –  If previously removed, carefully open out new circlip -1- and guide it over splines for 5th/6th gear synchro-hub -3-. l  It should not be possible to turn the circlip in the annular groove on the input shaft by hand

–  Install 5th speed selector gear -B-. l  When rotated, selector gear -B- must not come into contact with circlip -A-. l  There must be a uniform clearance -x- between selector gear and circlip all round. Note the following when performing the following steps: –  Fit input shaft in drilling of support bridge -2011-. –  Position drift sleeves on centre of heated components (synchro-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.

Press on synchro-hub for 5th and 6th gear as follows: –  Fit 5th gear synchro-ring. –  Press on pre-heated synchro-hub as far as stop. –  Slide locking collar over synchro-hub.

Determining thickness of circlip for synchro-hub for 5th and 6th 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)
2.44	2.47	2.50

–  Fit locking collar for 5th/6th gear on synchro-hub. –  Install 6th speed selector gear with needle bearing and synchro-ring.

–  Fit thrust washer -A-. –  Press on pre-heated needle bearing inner race -B- for 3rd speed selector gear. –  Install 3rd speed selector gear with needle bearing and synchro-ring.

Installation position of 3rd/4th gear synchro-hub and locking collar l  The lower inside collar -arrow A- of the synchro-hub faces 4th gear.   Note If there is a groove -arrow B- on the locking collar -2-, this may face towards 3rd or 4th gear.

Pressing on pre-heated 3rd/4th gear synchro-hub –  Fit locking collar for 3rd/4th gear on synchro-hub.

Pressing on pre-heated needle bearing inner race -A- for 4th speed selector gear –  Install 4th speed selector gear together with needle bearing and synchro-ring.

–  Fit thrust washer -A-. –  Press on pre-heated inner race -B- for roller bearing. –  Then check all selector gears for freedom of movement and axial play. l  The axial play of the selector gears must be at least 0.15 mm.   Note Tighten bolt securing input shaft to specified torque → Anchor.