Input Shaft Assembly Overview: Notes
WARNING: This page is about a different car, the 2010 Audi A5. However, it is still accessible from the selected car via links, so may be relevant.
Removing the input shaft from the output shaft and the bearing bracket. Refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
Disassembling and assembling input shaft - assembly sequence. Refer to INPUT SHAFT .
NOTE:
- When installing new gears or input shaft, note technical data. Refer to SPECIFICATIONS .
- Insert all bearings and synchronizer rings on input shaft with transmission fluid.
- Remove the locking ring -10- only to replace the roller bearing -7-.
- After installing, the 3rd through 6th gears must have an axial play of 0.15 to 0.50 mm.
- Securing Ring
- Determining thickness, refer to TRANSMISSION, ASSEMBLY SEQUENCE
- Transmission Housing
- Ball Bearing
- For input shaft
- Removing and installing, refer to item -18- under TRANSMISSION HOUSING
- Securing Ring
- Observe installed location, refer to TRANSMISSION HOUSING
- Sealing Plug
- For input shaft
- Installing, refer to INPUT SHAFT ASSEMBLY OVERVIEW .
- Input Shaft
- With splines for the 1st, 2nd and Reverse gear
- There is a plug in the hole, near the clutch plate splines -5-
- Install the plug when replacing the input shaft, refer to INSTALLING THE PLUG -1- IN THE INPUT SHAFT .
- Checking the input shaft for wear, refer to CHECKING THE INPUT SHAFT FOR WEAR .
- Roller Bearing
- Always replace
- For input shaft
- Pressing off, refer to PRESS ROLLER BEARING OFF INPUT SHAFT. .
- Pressing on, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Bearing Bracket
- Supports input shaft and input shaft in transmission cover
- Refer to item -3- under SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
- Needle Bearing
- For 5th gear
- Installation location, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Securing Ring
- Identify
- Do not exchange with the locking ring -16-
- Installation location, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Always replace after removing
- Must not be turned by hand in the groove all around the input shaft
- Must not contact the 5th gear wheel when turning the gear, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- 5th Gear Wheel
- Must not contact the locking ring when turning the gear, refer to item -10- under CHECKING SYNCHRONIZER RING FOR WEAR .
- Spring
- Inserting in 5th gear selector gear, refer to INSERTING SPRING INTO SELECTOR GEAR .
- Synchronizer Ring for 5th Gear
- Checking for wear, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Synchronizer Hub for 5th and 6th Gears
- Installed position: the shorter spline faces the 6th gear up to the groove, refer to INSTALLED POSITION: LOCKING COLLAR AND 5TH/6TH GEAR SYNCHRONIZER HUB .
- Locking Collar for 5th and 6th Gear
- Installed position: the groove faces the 6th gear, refer to INSTALLED POSITION: LOCKING COLLAR AND 5TH/6TH GEAR SYNCHRONIZER HUB .
- Securing Ring
- Identify
- Do not exchange with the locking ring -10-
- Determining thickness, refer to DETERMINING THE 5TH AND 6TH GEAR SYNCHRONIZER HUB LOCKING RING .
- Needle Bearing
- For 6th gear
- Synchronizer Ring for 6th Gear
- Checking for wear, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Spring
- Inserting in 6th gear wheel, refer to INSERTING SPRING INTO SELECTOR GEAR .
- 6th Gear Wheel
- Thrust Washer
- For 3rd and 6th gear selector gears
- Inner Race/Needle Bearing
- For 3rd gear
- Needle Bearing
- For 3rd gear
- 3rd Gear Wheel
- Spring
- Inserting in 3rd gear selector gear, refer to INSERTING SPRING INTO SELECTOR GEAR
- Synchronizer Ring for 3rd Gear
- Checking for wear, refer to CHECKING SYNCHRONIZER RING FOR WEAR .
- Synchronizer Hub for 3rd and 4th Gears
- Installed position: shoulder faces 4th gear, refer to INSTALLED POSITION: LOCKING COLLAR -2- AND REVERSE GEAR WHEEL -1- .
- Locking Collar for 3rd and 4th Gear
- Installed position: the groove faces the 4th gear, refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
- Inner Race/Needle Bearing
- For 4th gear
- Needle Bearing
- For 4th gear
- 4th Gear Synchronizer Ring
- Checking for wear, refer to INSERTING SPRING INTO SELECTOR GEAR .
- Spring
- Inserting in 4th gear wheel, refer to INSERTING SPRING INTO SELECTOR GEAR .
- 4th Gear Wheel
- Thrust Washer
- For 4th gear selector gear
- Inner Race
- For the roller sleeve -37- inside the transmission cover
- Bolt
- 200 Nm
- Coat with locking fluid AMV 185 101 A1
- Roller Sleeve
- Install in the transmission cover
- Removing and installing, refer to item -6- under TRANSMISSION COVER