Output Shaft, Disassembling And Assembling

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Press Plate VW401
Press Plate VW402
Press Piece - Rod VW407
Press Piece - Multiple Use VW412
Press Piece - 60mm VW415A
Press Piece - Multiple Use VW519
Slide Hammer Set VW771
Seal/Bearing Installer - Sleeve 32-109
Bearing Installer - Differential Bearing 40-21
Seal Installer - Steering Rack 3013
Press Piece - Reverse Gear Syncro 3296
Puller - Kukko Internal - 12-16mm 21/1
Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2
Inductive Heater VAS6414

NOTE:

Removing and installing 1st, 2nd and reverse gears is described in. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING .

Fig 1: Identifying 4th Gear Wheel, Removal

Courtesy of AUDI OF AMERICA, LLC

-- Remove the spacer sleeve from the output shaft by hand. Refer to -item 33- "Spacer Sleeve"

Fig 2: Identifying 3rd Gear Wheel, Removal

Courtesy of AUDI OF AMERICA, LLC

A - Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2

Fig 3: Identifying Roller Bearing From Output Shaft, Removal

Courtesy of AUDI OF AMERICA, LLC

A - Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2

NOTE:

The roller bearing will get damaged when it is being removed, therefore always replace it.

If the output shaft was replaced, the roller bearing does not have to be pressed out of the output shaft.

The roller bearing cage can also get damaged when removing using a screwdriver. Then mount the Separating Tool on the inner race.

Fig 4: Identifying Roller Bearing On Output Shaft, Installation

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Pressing On Gear-Wheel For 3rd Gear

Courtesy of AUDI OF AMERICA, LLC

Installed position:

High inner collar faces 4th gear.

-- Install the spacer sleeve on the output shaft by hand. Refer to -item 33- "Spacer Sleeve".

Fig 6: Pressing On Gear-Wheel For 4Th Gear

Courtesy of AUDI OF AMERICA, LLC

Installed position:

The high inside collar faces upward, to the groove for the locking ring

-- Install the 4th gear wheel locking ring.

When replacing the output shaft, the spacer sleeve or the 3rd or 4th gear wheels:

Determine the 4th gear wheel locking ring .

Fig 7: Determining Thickness Of Circlip

Courtesy of AUDI OF AMERICA, LLC

The gear wheel is installed all the way.

NOTE:

The 4th gear wheel locking ring is determined the same as with the synchronizer hub.

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

The following circlips are available:

Circlip thickness (mm)
2.35	2.41	2.47
2.38	2.44	2.50

Fig 8: Pulling Out Flange Shaft/Pinion Needle Bearing

Courtesy of AUDI OF AMERICA, LLC

A - Internal Puller 12 to 14.5 mm, for example 21/1

Fig 9: Driving In Flange Shaft/Pinion Needle Bearing Flush

Courtesy of AUDI OF AMERICA, LLC

Transmission with needle bearing

The larger diameter on the Seal Installer - Steering Rack 3013 points to the needle bearing.
Install needle bearings with labeled side (thicker metal side) facing the Seal Installer - Steering Rack 3013.
Drive in the needle bearing flush in the output shaft.

Transmission with bearing bushing

The smaller diameter on the Seal Installer - Steering Rack 3013 points towards the bearing bushing.
Drive in the bearing bushing until the stop in the output shaft.