Dismantling and assembling output shaft for 3rd - 6th gear — AUDI

🧭 Before you start

Fits: Audi TT Mk2 (8J, 2006–2014)

• Special tools named: puller, feeler gauge

Don't miss

• When 5th gear wheel comes close to annular groove for circlip (arrow) during pressing procedure, secure output shaft to prevent it from dropping out.
• If 5th gear wheel has been pressed on in previous step, wait for output shaft to cool off.
• Pulling off tapered roller bearing inner race

📋 Procedure

1. Before applying puller, fit press toolVW 431 in output shaft and place thrust plate40-105 on it.
2. Remove circlip.
3. Place tools beneath 3rd speed selector gear so that no parts will be damaged during pressing. [Note: When 5th gear wheel comes close to annular groove for circlip (arrow) during pressing procedure, secure output shaft to prevent it from dropping out.]
4. Remove circlip.
5. Press inner ring onto cone on selector gear and measure gap (a) using a feeler gauge.

6. Press synchro-ring, outer ring and inner ring onto cone on selector gear and measure gap (a) using a feeler gauge.
7. Install 4th speed selector gear with needle bearing.
8. Place inner ring (A) on 4th speed selector gear.
9. Fit outer ring (B).
10. Fit synchro-ring (C).
11. Take off springs (1) before dismantling.
12. To assemble, slide locking collar over synchro-hub.
13. Insert locking pieces and install springs offset at 120°.
14. Fit circlip.
15. Install 3rd speed selector gear with needle bearing.
16. Heat 5th gear wheel to approx. 150° C.
17. Press on gear wheel quickly so that heat is not immediately transferred to output shaft.
18. Heat 6th gear wheel to approx. 150° C.
19. Fit circlip. [Note: If 5th gear wheel has been pressed on in previous step, wait for output shaft to cool off.]
20. Press on gear wheel quickly so that heat is not immediately transferred to output shaft.
21. Fit locking device for 6th gear wheel. [Note: Pulling off tapered roller bearing inner race]
22. Fit new shim with previous value under outer race.
23. Before applying puller, place thrust plate30-11 on output shaft.
24. Fit new shim with previous value under outer race.
25. Support clutch housing with tubeVW 415 A directly below bearing mounting.

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