Wheel Set, Disassembling And Assembling

Special tools and workshop equipment required 

• Press Piece - Multiple Use VW412
• Press Piece - 60mm VW415A
• Press Piece - Multiple Use VW519
• Press Piece - Output Shaft Gear/Final Drive Gear3002
• Shop Press VAG1290A
• Puller - Kukko 2-Arm - 70-180mm 20/10
• Puller - Kukko 2-Arm20/20 with Pulling Hook 300 mm
• Gearbox Support T40206
• Gearbox Assembly Tool T40213
• Inductive Heater VAS6414
• Hot Air Blower VAG1416

Disassembling

-- Secure the Gearbox Assembly Tool - Plate T40213/1 to the Gearbox Support T40206 using bolts -arrows-.

-- Insert the Gearbox Assembly Tool - Adapter T40213/5 and T40213/6 into the Gearbox Assembly Tool - Plate T40213/1.

-- Install the input shaft -1- together with the output shaft -2- and the shift fork group in the Gearbox Assembly Tool - Adapter T40213/5 and T40213/6.

• If it is necessary to disassemble the input shaft, then the internal multipoint bolt -A- in the shaft must be removed now using, for example, a torque wrench -D-. 
  Fig 3: If It Is Necessary To Disassemble Input Shaft, Then The Bolt -A- In Shaft Must Be Removed Now Using, For Example, A Torque Wrench

  Courtesy of AUDI OF AMERICA, LLC
• Shift 2 gears over the locking collars -B- and -C- in -direction of arrow-.
• The shafts must be in vertical position.

-- Then shift the locking collars back into the neutral position.

-- Remove the bolts -arrows- and remove the shift fork group from the bearing bracket.

-- Remove the 1st gear wheel -C- with the reverse gear synchronizer hub -B- and the reverse gear wheel inner race. 

-- Warm up the synchronizer hub -B-, using for example a Hot Air Blower VAG1416, to approximately 80 °C and remove with Two-Arm Puller.

A  - Two-Arm Puller, for example Puller - Kukko 2-Arm - 70-180mm 20/10 or 20/20

-- Remove the 1st/2nd gear synchronizer hub locking ring.

-- Remove the 2nd gear wheel -B-, the synchronizer hub and the 1st/2nd gear locking collar. 

A  - Two-Arm Puller for example 20/20 with 300 mm Pulling Hooks

-- Remove the bearing bracket -3- from the input and output shafts.

Assembling 

-- Place the Gearbox Assembly Tool - Plate T40213/1 with the Gearbox Assembly Tool - Adapters T40213/5 and T40213/6 on the Shop Press VAG1290A pressing table.

-- Position the output shaft -1- and input shaft -2- into the Gearbox Assembly Tool - Adapter T40213/5 and T40213/6

-- Install the bearing bracket over both shafts -3- ; the plastic part -4- faces upward.

-- Place inner race -2- on selector gear -1-.

-- Install the intermediate ring -3-. The tab -B- must be inserted into the recess -A-.

-- Insert the synchronizer ring -4-. Guide the tabs -C- through the recess -arrow-.

-- Install the 2nd gear wheel, the needle bearing and the synchronizer rings -A-. Place close attention to the position of the synchronizer rings. Refer to Fig 9.

• Heat the synchronizer hub to approximately 100 °C.
• Synchronizer hub installed position: the higher inside collar is facing the 2nd gear wheel.

-- Install the 1st/2nd gear synchronizer hub locking ring.

• When replacing the synchronizer hub or the output shaft:
  Fig 12: Determine Locking Ring -1- For 1st/2nd Gear Synchronizer Hub

  Courtesy of AUDI OF AMERICA, LLC

Determine the locking ring -1- for the 1st/2nd gear synchronizer hub  .

-- Determine thickest circlip which can still just be installed and insert it.

The following circlips are available:

Circlip thickness (mm)
2.44	2.47	2.50

-- Install the 1st/2nd gear synchronizer hub locking ring.

-- Mount the locking collar -1- over the pressed off synchronizer hub -2- so that the wire tooth spacing on the locking collar -arrow A- and on the synchronizer hub -arrow B- align with each other.

-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrows D- in locking collar.

-- Install the 1st gear wheel, the synchronizer rings and the needle bearings on the output shaft.

-- Install the thrust washer -A- and then install the heated inner race -B- for the reverse gear needle bearing. 

-- Install the reverse gear needle bearing, the gear wheel and the reverse gear locking collar. Refer to Figure.

-- Install the reverse gear synchronizer ring in the locking collar.

-- Heat the reverse gear synchronizer hub to approximately 100 °C.

-- Install the reverse gear synchronizer hub -A- with the synchronizer spring installed  . Refer to -item  7- "Synchronized Spring".

-- Secure the Gearbox Assembly Tool - Plate T40213/1 to the Gearbox Support T40206 using bolts -arrows-.

-- Secure the shift fork group -A- to the bearing bracket -C- with the bolts -B-. Tightening specification. Refer to -item  1- "Bolts".

• The Internal multipoint bolt -A- inside the input shaft must be tightened now with a torque wrench -D- to the tightening specification.Refer to -item  36- "Internal Multi-Point Bolt", if the input shaft was disassembled and assembled again. Clean the bolt threads with a wire brush and then install it with Locking Fluid AMV 185 101 A1.
  Fig 17: If It Is Necessary To Disassemble Input Shaft, Then The Bolt -A- In Shaft Must Be Removed Now Using, For Example, A Torque Wrench

  Courtesy of AUDI OF AMERICA, LLC
• Shift 2 gears over the locking collars -B- and -C- in -direction of arrow-.
• The shafts must be in vertical position.

-- Then shift the locking collars back into the neutral position.

-- Remove the input shaft together with the output shaft and the shift fork group from the Gearbox Assembly Tool - Plate T40213/1