Dismantling and assembling output shaft, 1st-4th gear — AUDI

02M
Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Press tool
VW 408 A Press tool
VW 412 Press tool
VW 415 A Tube

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 309 Holding plate
VW 313 Support clamp
VW 353 Gearbox support
VW 431 Press piece
VW 433 Press piece
VW 454 Press piece

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 512 Press disk
VW 516 Tube
VW 519 Tube
VW 771 Multi-purpose tool
VW 801 Holding plate
40-105 Thrust plate

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

40-20 Press tool
40-21 Press tool
2050 Thrust piece
3161 Extension
3235 Press
V.A.G 1582 Taper roller bearing puller
V.A.G 1582/7 Grip

1 - Kukko 21/7 Internal puller
1 - Internal puller Kukko 21/8
2 - Kukko 18/2 Puller
3 - Kukko 17/2 Separating device
4 - Kukko 22/2 Counter support

Notes:

When installing new gears or a new output shaft consult technical data
=>Page
00-3.
If the output shaft or taper roller bearings have been renewed then carry out output shaft adjustment => Page
35-45.

Clutch housing
Oil deflector ring
Dished washer
Pulling out => Fig.
1
Pressing in => Fig.
2

Outer race/taper roller bearing
Pulling out => Fig.
3
Pressing in => Fig.
4

Taper roller bearing inner race
Pressing off => Fig.
8
Pressing on => Fig.
9

Output shaft
For 1st-4th gear
Adjusting => Page
35-45

Needle roller bearing
For 2nd gear

2nd speed selector gear
Synchro-ring (Inner ring for 2nd gear)
Checking for wear
=> Fig.
10
Check lugs for scoring
Installation position => Fig.
12

2nd gear outer ring
Insert in the synchro-ring (item (9))
Renew if scored
Installation position => Fig.
12

2nd gear synchro-ring
Checking for wear
=> Fig.
11
Installation position => Fig.
12

1st and 2nd gear locking collar with synchro-hub
Pull off over bearing support after removing securing clip (item (13))
=> Fig.
7
Dismantling => Fig.
13
Assembling locking collar/synchro hub => Fig.
13 and Fig.
14
Installation position => Fig.
15
Pressing on => Fig.
16

Securing clip
1st gear synchro-ring
Checking for wear
=> Fig.
11
Assemble so that the recesses locate in the locking collar (item (12)
) locking pieces

1st gear outer ring
Insert in the synchro-ring (item (11)
), installation position
=> Fig.
17
Renew if scored

Synchro-ring (1st gear inner ring)
Checking for wear
=> Fig.
10
Check lugs for scoring
Installation position => Fig.
18

Needle roller bearing
For 1st gear

1st selector gear
Installation position => Fig.
19

Thrust washer
For 1st and 4th gear
Insert lugs on thrust washer in holes on output shaft

Washer
Holds thrust washer -item (19)
- in position on output shaft

Needle roller bearing
For 4th gear

Selector gear for 4th gear
4th gear synchro-ring
Checking for wear
=> Fig.
22

Locking collar with 3rd and 4th gear synchro-hub
Pull off by pulling off 4th speed selector gear after removing the circlip (item (25))
=> Fig.
6
Dismantling => Fig.
13
Installation position locking collar/synchro-hub => fig.
20
Assembling locking collar/synchro hub => Fig.
13 and Fig.
14
Pressing on => Fig.
21

Securing clip

3rd gear synchro-ring
Checking for wear
=> Fig.
11

Outer ring for 3rd gear
Insert in the synchro-ring (item (26)
), installation position
=> Fig.
17
Renew if scored

Synchro-ring (3rd gear inner ring)
Checking for wear
=> Fig.
10
Check lugs for scoring
Installation position => Fig.
18

Needle roller bearing
For 3rd gear

Selector gear for 3rd gear
Installation position => Fig.
19

Taper roller bearing inner race
Pulling off => Fig.
5
Pressing on => Fig.
23

Securing clip
Redetermine thickness if taper roller bearing -item (6)
- or output shaft -item (31)
- are replaced =>Fig.
24

Outer race/taper roller bearing
Pulling out => Fig.
25
Pressing in => Fig.
26

Shim
Determining thickness => Page
35-45

Gearbox housing

Fig.1
Pulling dished washer -A- out from output shaft

Fig.2
Pressing dished washer -A- in output shaft onto stop

Fig.3
Pulling taper roller bearing outer race out from gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 56 ... 70 mm, e.g. Kukko 21/8

Fig.4
Pressing taper roller bearing outer race into gearbox housing

Support gearbox housing with press tool 40-20 directly below bearing mounting.

Fig.5
Pulling off taper roller bearing inner race

First remove securing clip.
Before fitting puller, position press piece VW 431 in output shaft and set thrust plate 40-105 on it.

Fig.6
Pulling off 3rd and 4th gear synchro-hub/locking collar with 4th speed selector gear

First remove securing clip.

A - Puller, e.g. Kukko 18/2

B - Separating device 22 ... 115 mm, e.g. Kukko 17/2

Fig.7
Pressing off 1st and 2nd gear locking collar and synchro-hub

After removing securing ring press 2nd selector gear and locking collar/synchro-hub off together.

Fig.8
Pressing off taper roller bearing inner race

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

Fig.9
Pressing on taper roller bearing inner race

Fig.10
Checking inner ring for 1st, 2nd and 3 gear for wear

Press inner ring onto selector gear cone and measure gap "a" with a feeler gauge.

Gap "a" · New dimension · Wear limit
1st, 2nd and 3rd gear · 0.75 ... 1.25 mm · 0.3 mm

Fig.11
Checking 1st, 2nd and 3rd gear synchro-rings for wear

Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.

Gap "a" · New dimension · Wear limit
1st, 2nd and 3rd gear · 1.2 ... 1.8 mm · 0.5 mm

Fig.12
Installation position of outer ring, inner ring and 2nd gear synchro ring

Place inner ring -A- on 2nd speed selector gear

Angled lugs (arrow 1) point towards outer ring -B-.

Fit outer ring -B-.

Lugs (arrow 2) engage in selector gear recesses (arrow 3).

Fit synchro-ring -C-.

The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.

Fig.13
Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub

1 -
Spring
2 -
Locking piece
3 -
Locking collar
4 -
Synchro-hub

Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.

Fig.14
Assembling locking collar and synchro-hub for 1st/2nd gear and 3rd/4th gear

The locking collar has been pushed over the synchro-hub.

Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow locking piece.

Fig.15
Installation position of 1st and 2nd gear locking collar/synchro-hub

Identification groove -arrow 1- and narrow collar -arrow 2- of synchro-hub point towards 1st gear.

Fig.16
Pressing on 1st and 2nd gear locking collar/synchro-hub

Fig.17
Installation position for 1st or 3rd gear outer ring

Lugs (arrows) face towards synchro-hub/locking collar -A-

Fig.18
Installation position of synchro-ring (inner ring for 1st/3rd gear) -A-

The lugs (arrows 1) engage in the recesses (arrow 2) in the synchro-ring -B-.

Fig.19
Installation position of 1st and 3rd selector gears

The higher shoulder -A- faces toward 2nd or 4th gear -B-. The recesses in the shoulder (arrows) engage in the lugs of the outer ring (arrow => Fig.
17)

Fig.20
Installation position of 3rd and 4th gear locking collar/synchro-hub

The wider shoulder of the synchro-hub (arrow) faces towards 3rd gear.

Fig.21
Pressing on 3rd and 4th gear synchro-hub with locking collar

Install circlip.

Fig.22
Checking 4th gear synchro-ring for wear

Press synchro-ring onto selector gear cone and measure gap "a" with feeler gauge.

Gap "a" · New dimension · Wear limit
4th gear · 1.0 ... 1.7 mm · 0.5 mm

Fig.23
Pressing on taper roller bearing inner race

Fig.24
Determining thickness of circlip

Determine the thickest securing clip which will still just fit and install it.

The following securing clips are available:

Thickness (mm) · Spare Part No.
1.79 · 02M 311 187 G
1.83 · 02M 311 187 F
1.86 · 02M 311 187 E
1.89 · 02M 311 187 D
1.92 · 02M 311 187 C
1.95 · 02M 311 187 B
1.98 · 02M 311 187 A

Fig.25
Pulling taper roller bearing outer race out from gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

Fig.26
Pressing taper roller bearing outer race into gearbox housing

Fit shim under outer race.
Support gearbox housing with press piece 2050 directly below bearing support.