Dismantling and assembling output shaft (pinion shaft): Audi A3

🧭 Before you start

Fits: Audi A3 (8L, 1996–2003)

• Special tools named: puller, feeler gauge

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• Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.
• Before pressing on, place 1st gear synchro-ring on 1st speed selector gear.
• Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.

📋 Procedure

1. Fit adapter and apply tension to it behind the bearing rollers, then turn bearing and re-tension adapter.
2. Position splitter under 2nd speed selector gear and press off. [Note: Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.]
3. First remove circlip (arrow).
4. Before applying puller, insert an M10 x 20 hexagon bolt in hole in output shaft.
5. Fit thrust washer before pressing on inner race. Shoulder faces towards inner race.

6. Press synchro-ring onto tapered seat on selector gear and measure gap (a) with a feeler gauge.
7. Push locking collar over synchronising hub.
8. Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece. [Note: Before pressing on, place 1st gear synchro-ring on 1st speed selector gear.]
9. Press synchro-ring, outer ring and inner ring onto tapered seat on selector gear and measure gap (a) using a feeler gauge.
10. Press inner ring onto tapered seat on 2nd speed selector gear and measure gap (a) using a feeler gauge.
11. Install needle roller bearing, selector gear and synchro-ring for 3rd gear.
12. Push locking collar over synchronising hub.
13. Insert locking pieces and install springs offset at 120°. Angled end of spring must locate in hollow locking piece.
14. Install needle roller bearing, synchro-ring and 4th speed selector gear.
15. Fit thrust washer over 4th speed selector gear.

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