Wheel Set, Disassembling And Assembling

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 2016 Audi S4, 2016 Audi A4 Quattro, 2015 Audi S4, 2015 Audi A4 Quattro, and 2014 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Attach Plate T40213/1 To T40206 Using Bolts

Courtesy of AUDI OF AMERICA, LLC

-- 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.

NOTE:

Secure the Gearbox Assembly Tool - Adapter T40213/5 and T40213/6 using Gearbox Assembly Tool - Knurled Bolt T40213/3 after inserting the shafts.

-- 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.

Fig 2: Install Input Shaft Together With Output Shaft And Shift Fork Group Into Adapter T40213/5 And T40213/6

Courtesy of AUDI OF AMERICA, LLC

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.

NOTE:

Slightly turn the output shaft clockwise so that the locking collars -B- and -C- can be shifted back into the center position. Install the bolt back into the output shaft in order to turn the shaft. Refer to -item 2- "Bolt".

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

Fig 4: Identifying Bolts -Arrows- And Shift Fork Group From Bearing Bracket, Removal

Courtesy of AUDI OF AMERICA, LLC

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

Fig 5: Removing 1st Gear Wheel -C- With Reverse Gear Synchronizer Hub -B- And The Reverse Gear Wheel Inner Race

Courtesy of AUDI OF AMERICA, LLC

-- 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

CAUTION:

Danger of causing damage to the splines on the first gear wheel -C-.

The hooks on the two-arm puller must not touch the spline camber on the 1st gear wheel.

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

Fig 6: Identifying 2nd Gear Wheel Synchronizer Hub And 1st/2nd Gear Locking Collar, Removal

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 7: Identifying Plate T40213/1 With Adapters T40213/5 And T40213/6 On VAG 1290 A Table, Installation

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Output Shaft -1-, Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

Input Shaft -2-, Disassembling and Assembling. Refer to INPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

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.

Fig 8: Identifying Plate T40213/1 With Adapters T40213/5 And T40213/6 On VAG 1290 A Table, Installation

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 9: Identifying Installation Position Of Synchronizer Rings For 1st And 2nd Gear

Courtesy of AUDI OF AMERICA, LLC

NOTE:

If the parts are not to be replaced, make sure they are reallocated to their original gear.

-- 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.

Fig 10: Identifying 2nd Gear Wheel, Needle Bearing And Synchronizer Rings -A-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The tabs -arrows- on the synchronizer rings must fit into the openings on the synchronizer hub when installing the 1st/2nd gear synchronizer hub.

Fig 11: Identifying 1st/2nd Gear Synchronizer Hub

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.

-- 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.

Fig 13: Identifying Assembly Of Locking Collar/Synchronizer Hub For 1st And 2nd Gear

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 14: Identifying Thrust Washer -A- And Heated Inner Race -B- For Reverse Gear Needle Bearing, Installation

Courtesy of AUDI OF AMERICA, LLC

-- 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".

Fig 15: Identifying Reverse Gear Synchronizer Hub -A- With Spring Installed

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The tabs -arrow- on the synchronizer ring must lock into the openings in the reverse gear synchronizer hub.

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

Fig 16: Attach Plate T40213/1 To T40206 Using Bolts

Courtesy of AUDI OF AMERICA, LLC

-- 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.

NOTE:

Turn the input shaft by the bolt -A- slightly counter-clockwise so that the locking collars -B- and -C- can be shifted again into the center position.

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