Dismantling and assembling drive pinion — AUDI

Dismantling and assembling drive pinion on Audi: factory workshop procedure. Full factory text, tools and checks.

Workshop procedure for AUDI — the factory write-up, straight from real workshop data.

factory workshop text

📋 Procedure

Notes:

When installing new gears or final drive set, refer to => Technical data,Page
00-3
.
Adjustments are required when replacing components marked 1) => Adjustment overview, Page
39-25
.

Gearbox housing
Servicing => Page
34-97

Shim "S3"
Adjustment overview => Page
39-25

Outer race for large taper roller bearing 1)
Pulling out =>Fig.
1
Pressing in =>Fig.
2
and Fig.
3

Drive pinion 1)
Paired with crown wheel (final drive set)

Inner race for large taper roller bearing 1)
Pressing off => Fig.
8
Pressing on => Fig.
9
Low friction bearing; do not oil when measuring frictional torque

4th gear wheel
Pressing off => Fig.
7
Pressing on => Fig.
10

Spacer sleeve
3rd gear wheel
Pressing off together with -item
9
- => Fig.
6
Pressing on => Fig.
11

Inner race for 2nd speed sliding gear
Pressing off together with -item
8
- => Fig.
6
Pressing on => Fig.
12

Needle roller bearing for 2nd speed sliding gear
Oil with gear oil before installing

2nd gear sliding wheel
Pressing off => Fig.
5
Before installing, fit spring and slide needle roller bearing onto hollow shaft
After installing, check axial clearance with a feeler gauge
(0.15...0.35 mm)

Synchro-ring for 2nd gear
Checking for wear => Fig.
35-9
Replace synchro-ring with fine pitch thread with synchro-ring coated with Molybdenum

Synchro-hub for 1st and 2nd gear
Pressing off => Fig.
5
Pressing on => Fig.
13
Installation position: Flush hub towards 2nd speed sliding gear

Locking collar, 1st and 2nd gear
Installation position: Groove for selector fork towards 1st speed sliding gear

Synchro-ring for 1st gear
Checking for wear => Fig.
35-9

Inner race for 1st speed sliding gear
Pressing off => Fig.
5
Pressing on => Fig.
14

Needle roller bearing for 1st speed sliding gear
Oil with gear oil before installing

1st speed sliding gear
Before installing insert spring => Fig.
35-9
After pressing on -item
19
-, check axial clearance using a feeler gauge (0.15...0.50 mm)

Inner race for small taper roller bearing 1)
Pressing off => Fig.
4
Pressing on => Fig.
15
Low friction bearing; do not oil when measuring frictional torque

Outer race for small taper roller bearing 1)
Driving out => Fig.
16
Pressing in =>Fig.
17

Shim "S4"
Adjustment overview => Page
39-25

AUDI? This is the factory text for the model family — variants differ. Check it against your exact car. Check my car — free →

Bearing plate 1)
Servicing => Page
34-83

Circlip
Re-determining thickness for 5 -speed gearbox => Page
34-60
Re-determining thickness for 6 -speed gearbox => Page
34-62

6th gear wheel
Not fitted in 5-speed gearboxes
Pressing off => Page
34-54
Pressing on => Page
34-55
Installation position: Shoulder towards inner race for small taper roller bearing

Circlip
Re-determining thickness for 5 -speed gearbox => Page
34-60
Position behind -item
23
- for 5-speed gearbox
Re-determining thickness for 6 -speed gearbox => Page
34-62

5th gear wheel
Pulling off => Page
34-49
Driving on => Page
34-67

Circlip
End cover
Servicing => Page
34-73

Fig.1
Pulling out outer race for large taper roller bearing

Stepped side of thrust pad 3062 rests against the outer race

Fig.2
Heating gearbox housing in order to fit outer race for taper roller bearing

Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100 oC, with a hot air blower.

Fig.3
Inserting outer race for large taper roller bearing in gearbox housing and press home

Insert outer race only after heating gearbox housing and push into position for 1...2 minutes under a repair press until a heat exchange has taken place.

Fig.4
Pressing off inner race of small taper roller bearing for drive pinion together with 1st speed sliding gear