5/6-speed manual gearbox 02M/02Y, four-wheel drive — Dismantling and assembling output shaft for 1st - 4th gear — AUDI
5/6-speed manual gearbox 02M/02Y, four-wheel drive — Dismantling and assembling output shaft for 1st - 4th gear on Audi: 17 steps.
Workshop procedure for AUDI — the exact step sequence and torque figures, straight from real workshop data.
🧭 Before you start
Fits: Audi A3 (8L, 1996–2003)
- Special tools named: puller, feeler gauge
📋 Procedure
- Place drift sleeve40-20 directly under bearing mounting to support clutch housing.
- Before fitting puller, position press toolVW 431 in output shaft and set thrust plate40-105 on it.
- First remove circlip.
- First remove circlip.
- Press off 2nd speed selector gear and locking collar/synchronising hub together.
- Press inner ring against tapered seat on selector gear and measure gap (a) using a feeler gauge.
- Press synchro-ring, outer ring and inner ring against tapered seat on selector gear and measure gap (a) using a feeler gauge.
- Place inner ring (A) on 2nd speed selector gear.
- Position outer ring (B) on gear.
- Position synchro-ring (C) on gear.
- Slide locking collar onto synchro-hub.
- Insert locking pieces and install springs 120° off-set.
- Press synchro-ring against tapered seat on selector gear and measure gap (a) using a feeler gauge.
- Determine required thickness and fit circlip .
- Determine the thickest circlip which will just fit and install it.
- First fit shim under outer race.
- Place thrust piece2050 directly under bearing mounting to support gearbox housing.
Other AUDI procedures
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- Removing engine – Audi A8 D3 · 41 torque figures
- Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
- Installing engine – Audi A8 D4 · 36 torque figures
- Removing and installing camshaft timing chain · 29 torque figures
- Removing and installing natural gas tank 5, Caddy Maxi · 1 torque figures
- Checking holding pressure – Audi 2.0
- Assembly overview - sump, oil pump · 2 torque figures
- Removing and installing belt pulley on alternator, driven by poly V-belt · 1 torque figures
- Removing and installing side airbag on driver side and front passenger side, up to 2010 · 1 torque figures
Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.