Audi Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Tube -VW 519-

t	Multi-purpose tool -VW 771-

t	Tube -32 - 109-

t	Drift sleeve -40 - 21-

t	Punch -3013-

t	Tube -3296-

t	-1-Internal puller -Kukko 21/1-

t	-3-Splitter -Kukko 17/2-

t  Inductive heater -VAS 6414-   Note Removing and installing 1st, 2nd and reverse gears is described under → Chapter „Assembly sequence - removing and installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft“. Pressing 3rd gear wheel, 4th gear wheel and roller bearing off output shaft –  Remove circlip for 4th gear wheel

Pressing off 4th gear wheel –  Detach spacer sleeve → Item from output shaft by hand.

Pressing off 3rd gear wheel A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing roller bearing off output 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  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. Pressing 3rd gear wheel, 4th gear wheel and roller bearing onto output shaft

Pressing roller bearing onto output shaft

Pressing on 3rd gear wheel t  Installation position: Higher inside collar faces 4th gear. –  Fit spacer sleeve → Item onto output shaft by hand.

Pressing on 4th gear wheel t  Installation position: Higher inside collar faces upwards towards circlip groove. –  Fit circlip for 4th gear wheel. l  If the output shaft, spacer sleeve or 3rd or 4th gear wheels are being renewed:

Determine thickness of new circlip for 4th gear wheel. l  Gear wheel is pressed on as far as stop.   Note The thickness of the circlip for the 4th gear wheel is determined as shown for the synchronising 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)
2.35	2.41	2.47
2.38	2.44	2.50

Pulling out needle bearing for rear flange shaft in output shaft A -  Internal puller 12 ... 14.5 mm, e.g. -Kukko 21/1-

Driving in needle bearing for rear flange shaft in output shaft until flush Install needle bearing so the lettering (side with thicker metal) faces towards the punch -3013-.