3rd to 6th gear assembly overview, removing and installing

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Sequence for disassembling and assembling → Disassembling and assembling sequence

NOTE:

3rd to 6th speed selector gears should have an axial play of 0.20to 0.50mm after installing.

Fig 1: 3rd To 6th Gear Assembly Overview

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1 - Bearing housing

With input shaft and output shaft

2 - Oil collector

With magnet
Clipped into reverse shaft support.

3 - Circlip

Install thickest circlip that will still just fit.
Re-determining thickness → Disassembling and assembling sequence

4 - 6th gear wheel

5 - Spacer sleeve

6 - 5th gear wheel

Installation position: high inside collar faces 4th gear wheel

7 - 4th gear wheel

Installation position: high inside collar faces 5th gear wheel

8 - Circlip

Install thickest circlip that will still just fit.
Re-determining thickness → Disassembling and assembling sequence

9 - 3rd gear wheel

Installation position: machined side faces reverse gear synchronizing hub

10 - Thrust washer

For 3rd speed selector gear

11 - Needle bearing

For 3rd gear

12 - 3rd speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

13 - 3rd gear synchro-ring

Checking for wear Checking synchro-ring for wear

14 - Circlip

Mark

15 - Synchronizing hub for 3rd and 4th gear

Installation position: high inside collar faces 3rd speed selector gear

16 - Circlip

Re-determining thickness → Disassembling and assembling sequence

17 - Locking collar for 3rd and 4th gear

Mark position in relation to synchronizing hub prior to removing

18 - Selector fork for 3rd and 4th gear

19 - Pin with clip

For securing selector fork for 3rd and 4th gear to selector rod

20 - 4th gear synchro-ring

Checking for wear Checking synchro-ring for wear

21 - 4th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

22 - Needle bearing

For 4th gear

23 - Thrust washer

For 4th speed and 5th speed selector gears

24 - Needle bearing inner race

For 5th gear

25 - Needle bearing

For 5th gear

26 - 5th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

27 - 5th gear synchro-ring

Checking for wear Checking synchro-ring for wear

28 - Synchronizing hub for 5th and 6th gear

29 - Locking collar for 5th and 6th gear

Mark position in relation to synchronizing hub prior to removing

30 - Needle bearing inner race

For 6th gear

31 - Needle bearing

For 6th gear

32 - 6th gear synchro-ring

Checking for wear Checking synchro-ring for wear

33 - 6th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

34 - Thrust washer

For 6th speed selector gear

35 - Inner race

For needle roller bearing

36 - Multi-point socket head bolt, 150Nm

37 - Selector fork for 5th and 6th gear

38 - Pin with clip

For securing selector fork for 5th and 6th gear to selector rod