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 - Multiple Use VW412
Press Piece - 60mm VW415A
Slide Hammer Set VW771
Seal Installer - Steering Rack 3013
Press Piece - Bushing 3118
Press Piece - Reverse Gear Syncro 3296
Shop Press VAG1290A
Inductive Heater VAS6414
-1- Puller - Kukko Internal - 12-16mm 21/1
-3- Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm Kukko 17/2

NOTE:

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

Remove the 3rd and 4th Gear Wheels, Roller Bearings and Inner Race/2nd Gear Wheel Needle Bearing from the Output Shaft.

-- Remove the 4th gear wheel locking ring.

Fig 1: Removing the 4th Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Pressing force may be up to 200 kN (20 t).

Check the splines on the 4th gear wheel for damage after removing it.

Fig 2: Removing the 3rd Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Pressing force may be up to 200 kN (20 t).

Check the splines on the 3rd gear wheel for damage after removing it.

Fig 3: Identifying Roller Bearing With Inner Ring/Needle Bearing -D- For 2nd Gear And Thrust Washer -E- From Output Shaft

Courtesy of AUDI OF AMERICA, LLC

A -

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

NOTE:

Place the Separating Tool -A- underneath the bearing cage -B-.

Place bearing bracket -C- over roller bearing on output shaft so that the rollers are not pressed out of the bearing cage -B-.

The roller bearing cage can also get damaged when removing it with, for example, a screwdriver. Then mount the Separating Tool -A- on the inner race.

Install the 3rd and 4th Gear Wheels, Roller Bearings and Inner Race/2nd Gear Wheel Needle Bearing on the Output Shaft.

Fig 4: Identifying Roller Bearing On Output Shaft

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Installing Inner Race/Needle Bearing, 2nd Gear Wheel

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-- First fit the thrust washer -A- onto the roller bearing.

-- Next, heat the inner race/2nd gear wheel needle bearing up to approximately 100 °C (212 °F), and install all the way up to the stop.

WARNING:

Wear safety gloves.

Fig 6: Heat the 3rd Gear Wheel to a Maximum 150 Degrees C (302 Degrees F) and Install All the Way to the Stop

Courtesy of AUDI OF AMERICA, LLC

Installation position: The high inner collar -arrow- faces the 4th gear.

WARNING:

Wear safety gloves.

NOTE:

Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

Fig 7: Identifying 4th Gear Wheel

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Installation position: The high inner collar -arrow- faces the 3rd gear -A-.

WARNING:

Wear safety gloves.

NOTE:

Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

-- Install the 4th gear wheel locking ring.

Fig 8: Pulling Out Flange Shaft/Pinion Needle Bearing

Courtesy of AUDI OF AMERICA, LLC

A -

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

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

Courtesy of AUDI OF AMERICA, LLC

Install needle bearings with labeled side (thicker metal side) facing the Seal Installer - Steering Rack 3013.