Input shaft, pinion shaft/hollow shaft, reverse gear wheel and reverse selector gear, removing and installing: Notes

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Input Shaft, Pinion Shaft/Hollow Shaft, Reverse Gear Wheel And Reverse Selector Gear Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bearing housing

2 - Reverse gear wheel

With support for reverse shaft
Exploded view - reverse gear wheel Exploded view - reverse gear wheel

3 - Bolt -30 Nm-

4 - Reverse gear selector fork

5 - Pin with clip

For securing reverse gear selector fork to selector rod

6 - Circlip

Install thickest circlip that will still just fit.
Re-determining thickness → Disassembling and assembling sequence

7 - 3rd gear wheel

Installation position: machined side faces reverse gear synchronizing hub

8 - Reverse gear locking collar

Mark position in relation to synchronizing hub prior to removing
Installation position: taper faces reverse gear synchro-ring

9 - Reverse gear synchronizing hub

Installation position: high inside collar faces 3rd gear wheel

10 - Synchronizing ring for reverse gear

Checking for wear Checking synchro-ring for wear

11 - Reverse selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

12 - Needle bearing

For reverse gear

13 - Pinion shaft

With inner race/double tapered roller bearing and needle bearing
Disassembling and assembling → Pinion shaft and hollow shaft

14 - Needle bearing

For pinion shaft/hollow shaft
Remove needle bearing prior to pulling pinion shaft out of hollow shaft

15 - Hollow shaft

With 1st speed and 2nd speed selector gears
Disassembling and assembling

16 - Input shaft

Disassembling and assembling → Input shaft