Input shaft, assembly overview

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.

NOTE:

Refer to technical data when installing new gears → Code letters, allocation, transmission ratios, capacities .
Lubricate all bearings on input shaft with gear oil before installing.

Fig 1: Input Shaft, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Circlip

Mark
Installation position Installation position of circlips , - item 1 -
Determining thickness

2 - Ball bearing

Removing and installing → Disassembling and assembling sequence

3 - Circlip

Mark
Installation position Installation position of circlips , - item 2 -
Determining thickness

4 - Transmission housing

5 - Needle bearing

For input shaft

6 - Bolt, 24 Nm

7 - Input shaft

Adjusting → Input shaft, adjusting

8 - Roller bearing

Disassembling and assembling Detaching needle roller bearing from input shaft and installing needle roller bearing onto input shaft
Installation position: collar faces splines for 2nd gear

9 - Outer race

For needle roller bearing

10 - Bearing housing

11 - Thrust washer

For 3rd speed selector gear

12 - Needle bearing

For 3rd gear

13 - Circlip

Mark
Installation position Installation position of circlips , - item 3 -

14 - 3rd speed selector gear

15 - Spring

Insert in 3rd speed selector gear → Inserting spring in selector gear
Allocation of spring to selector gear

16 - 3rd gear synchro-ring

Checking for wear Checking synchro-ring for wear

17 - Synchronizing hub for 3rd and 4th gear

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

18 - Circlip

Mark
Installation position Installation position of circlips , - item 4 -
Re-determining thickness Determining thickness of circlip for synchronizing hub for 3rd and 4th gear

19 - Locking collar for 3rd and 4th gear

Mark position in relation to synchronizing hub prior to removing

20 - Needle bearing

For 4th gear

21 - 4th gear synchro-ring

Checking for wear Checking synchro-ring for wear

22 - Spring

Insert in 4th speed selector gear → Inserting spring in selector gear
Allocation of spring to selector gear

23 - 4th speed selector gear

24 - Thrust washer

For 4th speed and 5th speed selector gears

25 - Needle bearing inner race

For 5th gear

26 - Needle bearing

For 5th gear

27 - 5th speed selector gear

28 - Spring

Insert in 5th speed selector gear → Inserting spring in selector gear
Allocation of spring to selector gear

29 - 5th gear synchro-ring

Checking for wear Checking synchro-ring for wear

30 - Synchronizing hub for 5th and 6th gear

31 - Locking collar for 5th and 6th gear

Mark position in relation to synchronizing hub prior to removing

32 - Needle bearing inner race

For 6th gear

33 - Needle bearing

For 6th gear

34 - 6th gear synchro-ring

Checking for wear Checking synchro-ring for wear

35 - Spring

Insert in 6th speed selector gear Inserting spring in selector gear
Allocation of spring to selector gear

36 - 6th speed selector gear

37 - Thrust washer

For 6th speed selector gear

38 - Inner race

39 - Multi-point socket head bolt, 150Nm

40 - Multi-point socket head bolt, 24Nm

41 - Retaining plate

42 - Roller bearing

Bearing for input shaft in transmission cover
With lubricating unit
Always replace

43 - Transmission cover