Audi Workshop Service and Repair Manuals

Removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft - assembly sequence

Special tools and workshop equipment required

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Tube -VW 519-

t	Thrust piece -3002-

t	Workshop press -V.A.G 1290A-

t	-1-Two-arm puller -Kukko 20/10-

t	-1-Two-arm puller -Kukko 20-20- with 300 mm hooks

t  Gearbox support -T40206-

t  Separating tool -T40213-

t  Inductive heater -VAS 6414- Removing selector fork cluster, input shaft, 1st, 2nd and reverse gears from output shaft

–  Attach plate -T40213/1- to gearbox support -T40206- with bolts -arrows-. –  Fit adapters -T40213/5- and -T40213/8- in plate -T40213/1-.   Note Secure adapter -T40213/5- with knurled screw -T40213/3- after inserting shafts.

–  Insert input shaft -1- together with output shaft -2- and selector fork cluster in adapters -T40213/5- and -T40213/8-.

l  If you have to dismantle the input shaft, now loosen and unscrew the multi-point socket head bolt -A- in the input shaft using torque wrench -D- or similar. l  To do this, engage 2 gears by moving locking collars -B- and -C- in direction of -arrow-. l  The shafts must be vertical, as shown in illustration. –  Then move locking collars back to neutral position.   Note In order to move the locking collars -B- and -C- back into the centre position, turn the output shaft slightly in a clockwise direction. To turn the output shaft, screw the bolt → Item into the output shaft.

–  Remove bolts -arrows- and detach selector fork cluster from bearing mounting.

–  Pull off 1st speed selector gear -B- together with reverse gear synchro-hub and inner race for reverse selector gear. A -  Two-arm puller, e.g. -Kukko 20/10- or -Kukko 20-20-   Caution Risk of damage to dog teeth on 1st speed selector gear -B- Hooks of two-arm puller must not come into contact with dog teeth of 1st speed selector gear during removal. –  Detach circlip for 1st/2nd gear synchro-hub.

–  Pull off 2nd speed selector gear -B- together with synchro-hub and locking collar for 1st/2nd gear. A -  Two-arm puller, e.g. -Kukko 20-20- with 300 mm hooks –  Detach bearing mounting from input shaft and output shaft.   Note t  Dismantling and assembling output shaft → Chapter t  Dismantling and assembling input shaft → Chapter

Assembly (installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft) –  Place plate -T40213/1- with adapters -T40213/5- and -T40213/8- on work table of workshop press -V.A.G 1290A-. –  Insert output shaft -1- and input shaft -2- in adapters -T40213/5- and -T40213/8-. –  Fit bearing mounting -3- in correct position over the two shafts, with plastic piece -4- facing upwards.

Installation position of synchro-rings for 1st and 2nd 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-.

–  Fit 2nd speed selector gear together with needle bearing and synchro-rings -A-; note position of synchro-rings → Fig..   Note The stop lugs -arrows- on the synchro-ring must engage in the slots in the 1st/2nd gear synchro-hub when the synchro-hub is pressed on (next step).

Pressing on 1st/2nd gear synchro-hub l  Heat synchro-hub to approx. 100°C. l  Installation position of synchro-hub: high inside collar faces 2nd speed selector gear   Note When pressing on the synchro-hub, lift the 2nd speed selector gear slightly so that the stop lugs on the synchro-ring engage in the slots in the hub.

l  When renewing synchro-hub or output shaft: Determine thickness of new circlip -1- for 1st/2nd gear synchro-hub. –  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

–  Install circlip for 1st/2nd gear synchro-hub.

–  Fit locking collar -1- onto pressed-on synchro-hub -2- so that wide teeth of locking collar -arrow A- and synchro-hub -arrow B- coincide. –  Then fit thrust blocks -3- in synchro-hub and press them into recesses -arrows D- in locking collar. –  Install 1st speed selector gear with synchro-rings and needle bearing on output shaft.

–  Fit thrust washer -A- and pre-heated inner race -B- for reverse gear needle bearing. –  Fit reverse gear needle bearing together with selector gear and locking collar for reverse gear; note correct position → Fig.. –  Fit synchro-ring for reverse gear in locking collar. –  Heat synchro-hub for reverse gear to approx. 100°C.

–  Press on synchro-hub for reverse gear -A- with installed synchro-spring → Item.   Note When the synchro-hub for reverse gear is pressed on, the lugs -arrow- on the synchro-ring must engage in the slots in the hub.

–  Attach plate -T40213/1- to gearbox support -T40206- with bolts -arrows-. –  Secure selector fork cluster -A- to bearing mounting -C- with bolts -C-. Tightening torque → Item

l  If you have dismantled and assembled the input shaft, now tighten the multi-point socket head bolt -A- in the input shaft to the specified torque → Item using torque wrench -D-. Before installing the bolt, clean the thread with a wire brush and then apply locking fluid -AMV 185 101 A1-. l  To do this, engage 2 gears by moving locking collars -B- and -C- in direction of -arrow-. l  The shafts must be vertical, as shown in illustration. –  Then move locking collars back to neutral position.   Note In order to move the locking collars -B- and -C- back into the centre position, turn the input shaft slightly anti-clockwise via bolt -A-. –  Remove input shaft together with output shaft and selector fork cluster from plate -T40213/1-.