Dismantling and assembling output shaft for 1st through 4th gears — AUDI

📋 Procedure

1. Drive in dished washer until dimension (a) is obtained.
2. Support clutch housing with drift sleeve40-20 directly below bearing support.
3. Remove retaining ring for tapered roller bearing inner race on side facing gearbox housing.
4. Insert press toolVW 431 into output shaft and place thrust plate40-105 on that.
5. Pull off tapered roller bearing inner race using puller.

6. After pressing on, determine and install required retaining ring .
7. Determine thickest retaining ring which will still fit and install it. [Note: Allocation of retaining rings via Electronic Parts Catalogue [Note: After pulling out outer race, check shim for damage.]
8. Fit shim under tapered roller bearing outer race.
9. Support gearbox housing with thrust piece2050 below bearing support. [Note: Pull off tapered roller bearing inner race on side facing gearbox housing .]
10. First, remove retaining ring.
11. Then remove retaining ring and thrust washers for 1st and 4th gears .
12. Then remove synchromeshed gear for 1st gear with synchro-rings. [Note: Heat inner races of tapered roller bearings and synchro-hub with the inductive heaterVAS 6414 to approx. 100°C, and press them in to stop so there is no axial clearance.]
13. Place inner ring (1) on cone of synchromeshed gear.
14. Press outer ring (2) on cone of inner ring. Measure gap size (a) at 3 points offset by 120° using feeler gauge.
15. Make a note of average value.
16. Check inner surface of synchro-ring (arrow) for scoring and radial contact scoring, renew if necessary.
17. Place inner ring, outer ring and synchro-ring on cone of inner ring.
18. Press on synchro-ring with outer ring while simultaneously turning them in order to seat synchro-rings.
19. Measure gap size (a) at 3 points offset by 120° using feeler gauge.
20. Make a note of average value.
21. Position 2nd gear synchromeshed gear with needle bearing.
22. Place inner ring (A) on synchromeshed gear.
23. Fit outer ring (B).
24. Fit synchro-ring (C).
25. Slide locking collar over synchro-hub.
26. Fit locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
27. Install retaining ring.
28. Insert synchro-ring (A) into synchro-hub.
29. Insert outer ring (B) into synchro-ring.
30. Insert inner ring (C) into outer ring.
31. Install thrust washers for 1st and 4th gears , and retaining ring .
32. Position 4th gear synchromeshed gear with needle bearing.
33. Press synchro-ring onto cone of synchromeshed gear and measure gap (a) using feeler gauge.
34. Place 4th gear synchro-ring on 4th synchromeshed gear.
35. Turn synchro-ring so that grooves align with locking pieces.
36. Install retaining ring.
37. Insert synchro-ring (A) in synchro-hub for 3rd gear and 4th gear.
38. Insert outer ring (B) into synchro-ring.
39. Insert inner ring (C) into outer ring.
40. Install synchromeshed gear for 3rd gear with needle bearing. [Note: Press on tapered roller bearing inner race .Determine retaining ring for tapered roller bearing inner race .]

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