Output Shaft For 1ST To 4TH Gears Assembly Overview
WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Attach transmission to assembly stand. Refer to TRANSMISSION, SECURING TO ASSEMBLY STAND .
If output shaft or tapered roller bearings are replaced, an adjustment on output shaft must be performed. Refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING .
When installing new gears or a new output shaft, consult technical data. Refer to CODE LETTERS, ASSEMBLY ALLOCATION, RATIOS AND CAPACITIES .
Always replace both tapered roller bearings together as a set.
- Clutch Housing
- Oil Deflector Ring
- Dished Washer
- Pulling out PULL DISHED WASHER -A- OUT OF OUTPUT SHAFT
- Installing PRESSING DISHED WASHER IN OUTPUT SHAFT TO STOP
- Taper Roller Bearing Outer Race
- Pulling out PULLING OUT TAPERED ROLLER BEARING OUTER RACE
- Installing OUTPUT SHAFT, 1ST TO 4TH GEARS => Press the Outer Ring for the Tapered Roller Bearing into the Clutch Housing
- Tapered Roller Bearing Inner Race
- Pressing off PRESSING OFF INNER RACE FOR TAPERED ROLLER BEARING
- Pressing on PRESSING ON TAPERED ROLLER BEARING INNER RACE
- Output Shaft
- For 1st to 4th gear
- Adjusting, refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING
- Needle Bearing
- For 2nd gear
- 2nd Gear Selector Gear
- Synchronizer ring
- (Inner race for 2nd gear)
- Checking for wear CHECKING INNER RACE FOR 1ST GEAR, 2ND GEAR AND 3RD GEAR FOR WEAR
- Check tabs for scoring
- Installation location INSTALLED POSITION OF OUTER RACE, INNER RACE AND SYNCHRONIZER RING, 2ND GEAR
- Outer Race for 2nd Gear
- Install on synchronizer ring -9-
- Replace if grooved or scored
- Installation location INSTALLED POSITION OF OUTER RACE, INNER RACE AND SYNCHRONIZER RING, 2ND GEAR
- 2nd Gear Synchronizer Ring
- Checking for wear CHECKING SYNCHRONIZER RINGS FOR 1ST, 2ND AND 3RD GEARS FOR WEAR
- Installation location INSTALLED POSITION OF OUTER RACE, INNER RACE AND SYNCHRONIZER RING, 2ND GEAR
- Locking Sleeve with Synchronizer Hub for 1st and 2nd Gears
- After removing circlip -13-, press off gear wheel for 2nd gear PRESSING OFF LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS .
- Disassembling DISASSEMBLING AND ASSEMBLING LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS .
- Assembling locking collar/synchronizer hub DISASSEMBLING AND ASSEMBLING LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS
- Installation location INSTALLATION POSITION OF LOCKING COLLAR/SYNCHRONIZER HUB FOR 1ST AND 2ND GEAR
- Pressing on PRESSING ON LOCKING COLLAR/SYNCHRONIZER HUB FOR 1ST AND 2ND GEAR
- Securing Ring
- Synchronizer Ring for 1st Gear
- Checking for wear CHECKING SYNCHRONIZER RINGS FOR 1ST, 2ND AND 3RD GEARS FOR WEAR
- Insert so that holes engage in engagement pieces of locking collar -12-
- Outer Race for 1st Gear
- Insert into synchronizer ring -14-, installation position INSTALLATION POSITION OF OUTER RING FOR 1ST AND 3RD GEAR
- Replace if grooved or scored
- Synchronizer Ring
- (Inner race for 1st gear)
- Checking for wear CHECKING INNER RACE FOR 1ST GEAR, 2ND GEAR AND 3RD GEAR FOR WEAR
- Check tabs for scoring
- Installation location INSTALLED POSITION OF SYNCHRONIZER RING -A- (INNER RING FOR 1ST AND 3RD GEAR)
- Needle Bearing
- For 1st gear
- 1st Gear Selector Gear
- Installation location OUTPUT SHAFT FOR 1ST TO 4TH GEARS ASSEMBLY OVERVIEW
- Thrust Washers
- For 1st and 4th gear
- Quantity: 2
- Insert tab of thrust washer in output shaft hole
- Securing Ring
- Holds thrust washers -19- in position on output shaft
- Needle Bearing
- For 4th gear
- 4th Gear Selector Gear
- 4th Gear Synchronizer Ring
- Checking for wear CHECKING SYNCHRONIZER RING FOR 4TH GEAR FOR WEAR
- Locking Collar with Synchronizer Hub for 3rd and 4th Gear
- After removing circlip -25-, pull off gear wheel for 4th gear DISASSEMBLING AND ASSEMBLING LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS .
- Disassembling DISASSEMBLING AND ASSEMBLING LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS
- Installation position of locking collar/synchronizer hub INSTALLATION POSITION OF LOCKING COLLAR/SYNCHRONIZER HUB FOR 3RD AND 4TH GEAR
- Assembling operating sleeve/synchronizer hub DISASSEMBLING AND ASSEMBLING LOCKING COLLAR AND SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS and ASSEMBLING LOCKING COLLAR/SYNCHRONIZER HUB FOR 1ST AND 2ND GEARS AS WELL AS 3RD AND 4TH GEARS
- Pressing on PRESSING ON SYNCHRONIZER HUB WITH LOCKING COLLAR FOR 3RD AND 4TH GEARS
- Securing Ring
- Synchronizer Ring for 3rd Gear
- Checking for wear CHECKING SYNCHRONIZER RINGS FOR 1ST, 2ND AND 3RD GEARS FOR WEAR
- Outer Race for 3rd Gear
- Insert into synchronizer ring -26-, installation position INSTALLATION POSITION OF OUTER RING FOR 1ST AND 3RD GEAR
- Replace if grooved or scored
- Synchronizer Ring
- (Inner race for 3rd gear)
- Checking for wear CHECKING INNER RACE FOR 1ST GEAR, 2ND GEAR AND 3RD GEAR FOR WEAR
- Check tabs for scoring
- Installation location INSTALLED POSITION OF SYNCHRONIZER RING -A- (INNER RING FOR 1ST AND 3RD GEAR)
- Needle Bearing
- For 3rd gear
- 3rd Gear Selector Gear
- Installation location INSTALLATION POSITION OF SELECTOR GEAR FOR 1ST AND 3RD GEAR
- Tapered Roller Bearing Inner Race
- Pulling off PULLING OFF INNER RACE FOR TAPERED ROLLER BEARING
- Pressing on PRESSING ON TAPERED ROLLER BEARING INNER RACE
- Securing Ring
- When replacing tapered roller bearing -31- and output shaft -6-, determine again
- Taper Roller Bearing Outer Race
- Adjustment Shim
- Determining thickness, refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING
- Transmission Housing