Assembling output shaft for 1st - 4th gear, from gearbox manufacturing date 26 10 9 to 24 05 0 — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012), Audi TT Mk2 (8J, 2006–2014)

• Special tools named: feeler gauge
• Renewed: if necessary

Don't miss

• Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.
• Pressing on tapered roller bearing inner race on gearbox housing end Determining thickness of circlip for tapered roller bearing inner race

📋 Procedure

1. Place inner ring (1) onto cone of selector gear.
2. Press outer ring (2) against cone of inner ring. Measure gap (a) with feeler gauge at 3 points spaced 120° apart.
3. Note down mean value.
4. Check inner friction surface of synchro-ring (arrow) for grooves or radial scoring and renew if necessary.
5. Place inner ring, outer ring and synchro-ring onto cone of selector gear.

6. Press down and simultaneously rotate synchro-ring with outer ring to achieve proper seating.
7. Measure gap (a) with feeler gauge at 3 points spaced 120° apart.
8. Note down mean value.
9. Install 2nd speed selector gear with needle bearing.
10. Place inner ring (A) on selector gear.
11. Fit outer ring (B).
12. Fit synchro-ring (C).
13. Slide locking collar over synchro-hub.
14. Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.
15. Fit circlip.
16. Fit synchro-ring (A) in synchro-hub.
17. Fit outer ring (B) in synchro-ring.
18. Fit inner ring (C) in outer ring.
19. Install thrust washers for 1st and 4th gear and circlip onto output shaft.
20. Install 4th speed selector gear with needle bearing.
21. Press synchro-ring onto cone of selector gear and measure gap dimension (a) with feeler gauge.
22. Fit 4th gear synchro-ring on 4th speed selector gear.
23. Turn synchro-ring so that grooves align with locking pieces.
24. Fit circlip.
25. Press inner ring onto cone on selector gear and measure gap (a) using a feeler gauge.
26. Press synchro-ring, outer ring and inner ring against cone on selector gear and measure gap (a) using a feeler gauge.
27. Fit synchro-ring for 3rd gear on synchro-hub/locking collar for 3rd and 4th gear
28. Install 3rd speed selector gear with needle bearing. [Note: Pressing on tapered roller bearing inner race on gearbox housing end Determining thickness of circlip for tapered roller bearing inner race]

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