5 and 6-speed manual gearbox 01E, front-wheel drive — Dismantling and assembling pinion shaft — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Renewed: synchro-ring

Don't miss

• Friction surface of intact synchro-ring has a graphite-grey, slightly porous appearance.
• Clean synchro-ring and make sure that friction surface is free of oil.
• The 4th gear wheel can also be pressed off together with the 3rd gear wheel and the inner race for the 3rd speed selector gear.

📋 Procedure

1. Press synchro-ring (E) into locking collar and measure gap (a) at positions (A), (B) and (C) using depth gauge(D).
2. Add the 3 measured values together and divide by 3. [Note: Friction surface of intact synchro-ring has a graphite-grey, slightly porous appearance.]
3. Clean synchro-ring and make sure that friction surface is free of oil.
4. Renew synchro-ring.
5. Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 °C, with a hot air blower.

6. ⚠ Wear protective gloves. — Insert outer race only after heating gearbox housing and press home under workshop press for a further 1 ... 2 minutes (approx.) until heat exchange has taken place. [Note: The 4th gear wheel can also be pressed off together with the 3rd gear wheel and the inner race for the 3rd speed selector gear.] [Note: Pressing off destroys bearing.]
7. ⚠ Wear protective gloves. — Heat inner race to approx. 100 °C and fit.
8. ⚠ Wear protective gloves. — Press home ensuring there is no axial play.
9. Heat gear to about 100 °C, fit and press home.
10. ⚠ Wear protective gloves. — Insert spacer sleeve (arrow).
11. Heat gear to about 100 °C, fit and press home.
12. ⚠ Wear protective gloves. — Heat inner race to approx. 100 °C and fit.
13. ⚠ Wear protective gloves. — Press home ensuring there is no axial play.
14. Lubricate needle bearing with oil.
15. Install needle bearing, selector gear with spring and synchro-ring for 2nd gear.
16. Heat synchro-hub to approx. 100 °C and fit.
17. ⚠ Wear protective gloves. — Press home ensuring there is no axial play.
18. Heat inner race to approx. 100 °C and fit.
19. ⚠ Wear protective gloves. — Press home ensuring there is no axial play.
20. Lubricate needle bearing with oil.
21. Install needle bearing, selector gear with spring and synchro-ring for 1st gear.
22. Heat inner race to approx. 100 °C and fit.
23. ⚠ Wear protective gloves. — Press home ensuring there is no axial play.
24. Insert shim "„S"4“ into bearing plate behind bearing seat.
25. Press in small tapered roller bearing outer race as far as stop.

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