5/6-speed manual gearbox 02M/02Y, four-wheel drive — Dismantling and assembling output shaft for 5th, 6th and reverse gear — AUDI

🧭 Before you start

Fits: Audi A3 (8L, 1996–2003)

• Special tools named: puller, feeler gauge

📋 Procedure

1. First fit washer under outer race.
2. Place drift sleeve40-20 directly under bearing mounting to support clutch housing.
3. First remove circlip.
4. Before applying puller, place press toolVW 431 and thrust plate40-105 on output shaft.
5. First remove circlip.

6. First remove circlip.
7. First remove circlip before pressing off sleeve (A).
8. Before applying puller, place thrust plate30-11 on output shaft.
9. Fit circlip after pressing on.
10. Install circlip after pressing on sleeve (A).
11. Press synchro-ring against tapered seat on selector gear and measure gap (a) using a feeler gauge.
12. Slide locking collar onto synchro-hub.
13. Insert locking pieces and install springs 120° off-set.
14. Fit circlip after pressing on.
15. Determine required thickness and fit circlip .
16. Determine the thickest circlip which will just fit and install it.
17. Place thrust piece2050 directly under bearing mounting to support gearbox housing.

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