Pinion and hollow shaft, disassembling and assembling: Notes

WARNING: This page is about a different car, the 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Pinion Shaft And Hollow Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 401 Pressure plate
VW 402 Pressure plate
VW 407 Press tool
VW 411 Press tool

VW 412 Press tool
VW 415 A Tubular section

Fig 2: Identifying Special Tools - Pinion Shaft And Hollow Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 416 B Tubular section
VW 418 A Tubular section
VW 429 Thrust collar
VW 447i Thrust pad

VW 454 Pressure piece
VW 519 Tubular section

Fig 3: Identifying Special Tools - Pinion Shaft And Hollow Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 771 Multi-purpose tool
40-103 Base
2010 Tubular section
3062 Thrust pad

3128 Puller
Kukko 17/2 Separating tool
Kukko 21/1 Internal puller

NOTE:

Fig 4: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Observe technical data when installing new gear wheels or drive unit. Refer to Code letters, assignment of mechanical units, transmission ratios and capacities .
When replacing parts marked 1) adjustments are required. Refer to Adjustment table .

1 - Transmission housing

2 - Shim "S3"

Adjustment table. Refer to Adjustment table

3 - Outer race for double tapered roller bearing 1)

Replace together with -item 5
Extracting. See Extracting outer race for double tapered roller bearing
Pressing in. See Pressing in outer race for double tapered roller bearing

Fig 5: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

4 - Pinion1)

Paired with ring gear, replace as assembly
Adjusting pinion and ring gear. Refer to General

5 - Inner race for double tapered roller bearing 1)

Replace
Gets damaged on removal
Pressing off. See Pressing off inner race for double tapered roller bearing
Pressing on. See Pressing on inner race for double tapered roller bearing

6 - Circlip

Determine thickness when replacing double tapered roller bearing. See Determining circlip

7 - Needle bearing

For pinion in hollow shaft
Lubricate with MoS2 grease

Fig 6: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

8 - Hollow shaft 1)

9 - Needle bearing for 1st gear

10 - Needle bearing for 1st gear

11 - 1st gear sliding gear

12 - Spring

Inserting in 1st gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

13 - 1st gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

14 - 1st and 2nd gear synchro-hub

Pressing off. See Pressing off 1st and 2nd gear synchro-hub
Pressing on. See Pressing on synchro-hub for 1st and 2nd gear

Fig 7: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

15 - Circlip

Mark
Installation position Installation position of circlips - item 1
Re-determining when replacing synchro-hub. See Determining circlip

16 - Needle bearing for 2nd gear

17 - 1st and 2nd gear locking collar

Installation position. See Installation position of locking collar for 1st and 2nd gear

18 - 2nd gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

19 - Spring

Inserting in 2nd gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

20 - 2nd gear sliding gear

Fig 8: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

21 - Circlip

Mark
Installation position Installation position of circlips - item 2

22 - 3rd gear wheel

Pressing off. See Pressing off 3rd gear wheel
Pressing on. See Pressing on 3rd gear wheel

23 - Circlip

Mark
Installation position Installation position of circlips - item 3
Re-determining when replacing 3rd gear wheel. See Determining circlip

24 - 4th gear wheel

Pressing off. See Pressing off 4th gear wheel
Pressing on. See Pressing on 4th gear wheel

25 - Circlip

Mark
Installation position Installation position of circlips - item 4
Re-determining when replacing 4th gear wheel. See Determining circlip

Fig 9: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

26 - Needle bearing

27 - 5th gear sliding gear

28 - Spring

Inserting in 5th gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

29 - 5th gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

30 - Circlip

Mark
Installation position Installation position of circlips - item 5

31 - Synchro-hub 5th gear and reverse gear

Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
Pressing on. See Pressing on synchro-hub for 5th gear and reverse gear

Fig 10: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

32 - Circlip

Mark
Installation position Installation position of circlips - item 6
Re-determining when replacing synchro-hub. See Determining circlip

33 - Needle bearing

For reverse gear

34 - Locking collar for 5th gear and reverse gear

Installation position. See Installation position of locking collar for 5th gear and reverse gear

35 - Reverse gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

36 - Spring

Inserting in reverse gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

Fig 11: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

37 - Reverse gear sliding gear

38 - Circlip

Mark
Installation position Installation position of circlips item 7

39 - Inner race for tapered roller bearing 1)

Pressing off. See Pressing off inner race for tapered roller bearing
Pressing on. See Pressing on inner race for tapered roller bearing

40 - Bushing

For securing outer race of small tapered roller bearing
Extracting. See Pulling out locking bushing for outer race of small tapered roller bearing
Does not need to be installed after small tapered roller bearing has been replaced

Fig 12: Transmission Housing, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

41 - Outer race for tapered roller bearing1)

Pressing out. See Pressing out outer race for tapered roller bearing
Pressing in. See Pressing in outer race for tapered roller bearing

42 - Shim "S4"

Adjustment table. Refer to Adjustment table

43 - Ring

For holding rubber washer
Assignment

44 - Rubber washer

For length compensation
Assignment

45 - Transmission cover