Checking Synchronizer Ring For Wear

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2016 Audi S5, 2015 Audi S5, 2014 Audi S5, 2013 Audi A5, and 2012 Audi A5. However, it is still accessible from the selected car via links, so may be relevant.

-- Press the synchronizer ring -E- into the locking collar and then measure the gap dimension -a- using a depth gauge -D- at -A-, -B- and -C-.

Fig 1: Checking Synchronizer Ring For Wear

Courtesy of AUDI OF AMERICA, LLC

-- Add measured values and divide by 3.

Determined value must not exceed 0.5 mm.

NOTE:

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

-- Install the roller bearing all the way onto the input shaft.

Fig 2: Installing Roller Bearing Onto Input Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Carefully expand the new locking ring -1- guide it over the splines on the 5th/6th gear synchronizer hub -3-.

Fig 3: Expanding New Locking Ring Guide Over Splines On 5th/6th Gear Synchronizer Hub

Courtesy of AUDI OF AMERICA, LLC

The locking ring must not be turned by hand in the groove all around the input shaft

-- Expand the needle bearing -2- on the 5th gear wheel and carefully guide id over the locking ring -1-. When doing this, do not lay the needle bearing on the collar -arrow- on the input shaft.

-- Install the 5th gear wheel -B-.

Fig 4: Installing 5Th Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

The gear wheel -B- must not touch the locking ring -A- while it is being turned.
There must be an even distance -x- between the gear wheel and the locking ring.

-- Install the 5th gear synchronizer ring.