Audi Workshop Service and Repair Manuals

Fitting sequence - detaching selector fork cluster, input shaft, first, second and reverse gear from output shaft/attaching

Special tools and workshop equipment required

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Thrust pad -VW 447 H-

t	Thrust plate -40 - 105-

t	Tube -3296-

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

t  Inductive heater -VAS 6414-

t  Gearbox support -T40206-

t  Separating tool -T40213-

t  -1-Two-arm puller -Kukko 20/10- t  -2-Extractor hook 200 mm 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-. –  Insert the adapters -T40213/7- and -T40213/9- in the plate -T40213/1-.   Note After inserting the input and output shaft, secure the adapter -T40213/7- with the knurled screw -T40213/3-.

–  Insert the input shaft -1- together with the output shaft -2- and the selector fork cluster -3- in the adapters -T40213/7- and -T40213/9-. –  Screw out the bolts -arrows- and detach the selector fork cluster from the bearing mounting -4-.

–  Detach the washer -A-, reverse gear synchronising hub -B- and reverse selector gear -C-.

–  Detach the 1st speed selector gear -E- with the inner race/needle bearing for reverse gear -C- and the thrust washer -D-. A -  Two-arm puller, e.g. -Kukko 20/10- B -  Extractor hook 200 mm   Caution Risk of damaging dog teeth at 1st speed selector gear -B-. When detaching, the extractor hooks of the two-arm puller must not be resting on the dog teeth of the 1st speed selector gear.

–  Detach the 2nd speed selector gear -E- with the inner race/needle bearing for 1st gear -C- and the synchronising hub/locking collar for 1st/2nd gear -D-. A -  Two-arm puller, e.g. -Kukko 20/10- B -  Extractor hook 200 mm

–  Detach the needle bearing -1-. –  Detach the bearing mounting -2- from the input shaft -4- and the output shaft -3-.   Note t  Dismantling and assembling output shaft → Chapter t  Dismantling and assembling input shaft → Chapter Installing selector fork cluster, input shaft, 1st, 2nd and reverse gears on output shaft

–  Position the plate -T40213/1- with the adapters -T40213/7- and -T40213/9- on the table of the workshop press -V.A.G 1290A-. –  Position the output shaft -1- and the input shaft -2- in the adapters -T40213/7- and -T40213/9-. –  Fit the bearing mounting -3- in installation position over the two shafts with the protrusions -arrows- facing upwards.

Installation position of synchro-rings for 1st, 2nd and reverse 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 the 2nd speed selector gear together with the needle bearing and synchro-rings.

Pressing on locking collar with 1st/2nd gear synchronising hub   Note t  Heat the synchronising hub to approx. 100 °C. t  Heed the installation position of the locking collar/synchronising hub → Fig.. t  When pressing on the synchronising hub, lift the 2nd speed selector gear slightly so that the lugs on the synchro-ring engage in the slots in the hub.

Heating inner race/needle bearing -A- for 1st speed selector gear to approx. 100 °C and pressing on

–  Fit the 1st speed selector gear -A- with the synchro-rings and needle bearing on the output shaft. –  Fit the thrust washer -B- and press on the heated inner race -C- for the reverse selector gear needle bearing.

–  Fit the reverse selector gear -C- with the needle bearing and reverse gear locking collar. –  Fit the reverse gear synchronising hub -B- with the synchro-rings and washer -A-.

–  Attach the plate -T40213/1- to the gearbox support -T40206-. –  Clean the threads of the bolts -arrows- with a wire brush. Then coat the bolts with locking fluid -AMV 185 101 A1-. –  Attach the selector fork cluster -3- with the bolts -arrows- to the bearing mounting -4-. –  Take the input shaft -1- together with the output shaft -2- and the selector fork cluster out of the plate -T40213/1-.