Drive pinion, disassembling and assembling: Notes

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Thrust tool
VW 408 A Pressure tool

VW 412 Thrust tool
VW 415 A Tube

Fig 2: Identifying Special Tools - Transmission, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

Crankshaft seal installing tool VW 204 B
VW 421 Tube
VW 455 Pressing-on sleeve
VW 519 Tube

VW 771 Multi-purpose tool
2010 Tube

Fig 3: Identifying Special Tools - Transmission, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

3005 Thrust plate
3118 Thrust piece
3128 Puller
3301 Assembly equipment

1 - Kukko 21//4 Internal puller
3 - Kukko 17/2 Separating tool

NOTE:

Fig 4: Exploded View Drive Pinion Up To Transmission Manufacture Date 22 06 3

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing new gears or the final drive set consult technical data. Refer to Code letters, application, ratios, capacities .
Adjustments are required when replacing components marked 1).

1 - Transmission housing 1)

2 - Shim "S3"

3 - Outer race for large tapered roller bearing 1)

Pulling out. See Pulling out outer race for large tapered roller bearing
Pressing in. See Pressing in outer race for large tapered roller bearing

4 - Drive pinion1)

Is mated with ring gear, replace together as a set
Adjusting ring gear and drive pinion. Refer to Drive pinion and ring gear, adjusting

5 - Inner race for large tapered roller bearing 1)

Always replace
Will be damaged during removal
Pressing off. See Pressing off inner race for large tapered roller bearing
Pressing on. See Pressing on inner race for large tapered roller bearing

6 - Circlip

Mark
Installation position Installation position of circlips - item 1
Re-determine thickness if tapered roller bearing is replaced. See Determining thickness of circlip

7 - Needle bearing for 1th gear

8 - 1st gear sliding gear

9 - Spring

Insert in 1st gear sliding gear. See Inserting spring in sliding gear
Allocation of spring to sliding gear

10 - Synchro-ring for 1st gear

Check for wear. See Checking synchro-ring for wear

11 - Synchro-hub for 1st and 2nd gear

Pressing off. See Pressing off synchro-hub for 1st and 2nd gear
Pressing on. See Pressing on synchro-hub for 1st and 2nd gear

12 - Circlip

Mark
Installation position Installation position of circlips - item 2
Re-determine if the synchro-hub is replaced. See Determining thickness of circlip

13 - Needle bearing for 2nd gear

14 - Locking collar, 1st and 2nd gear

Installation position. See Installation position of locking collar for 1st and 2nd gear

15 - Synchro-ring for 2nd gear

Check for wear. See Checking synchro-ring for wear

16 - Spring

Insert in 2nd gear sliding gear. See Inserting spring in sliding gear
Allocation of spring to sliding gear

17 - 2nd gear sliding gear

18 - Circlip

Mark
Installation position Installation position of circlips - item 3

19 - 3rd gear wheel

Pressing off. See Pressing off 3rd gear wheel
Shoulder points to 4th gear
Pressing on. See Pressing on 3rd gear wheel

20 - Circlip

Mark
Installation position Installation position of circlips - item 4
Re-determine thickness If the 3rd gear wheel is replaced. See Determining thickness of circlip

21 - 4th gear wheel

Pressing off. See Pressing off 4th gear wheel
Shoulder points to 3rd gear
Pressing on. See Pressing on 4th gear wheel

22 - Circlip

Mark
Installation position Installation position of circlips - item 5
Re-determine thickness if the 4th gear wheel is replaced. See Determining thickness of circlip

23 - Needle bearing

24 - 5th gear sliding gear

25 - Spring

Insert in 5th gear sliding gear. See Inserting spring in sliding gear
Allocation of spring to sliding gear

26 - Synchro-ring for 5th gear

Check for wear. See Checking synchro-ring for wear

27 - Circlip

Mark
Installation position Installation position of circlips - item 6

28 - 5th gear and reverse gear synchro-hub

Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
Pressing on. See Pressing on 5th gear and reverse gear synchro-hub

29 - Circlip

Mark
Installation position Installation position of circlips - item 5
If the synchro-hub is replaced re-determine. See Determining thickness of circlip

30 - Needle bearing

For reverse gear

31 - Locking collar for 5th and reverse gear

Installation position. See Installation position of locking collar for 5th and reverse gear

32 - Reverse gear synchro-ring

Check for wear. See Checking synchro-ring for wear

33 - Spring

Insert in reverse gear sliding gear. See Inserting spring in sliding gear
Allocation of spring to sliding gear

34 - Reverse gear sliding gear

35 - Inner race for small tapered roller bearing 1)

Pressing off. See Pressing off inner race for small tapered roller bearing
Pressing on. See Pressing on inner race for small tapered roller bearing

36 - Socket

To secure small tapered roller bearing outer race
Pulling out. See Pulling out securing bushing for small tapered roller bearing outer race
Need not be fitted after the small tapered roller bearing has been replaced.

37 - Outer race for small tapered roller bearing 1)

Pulling out. See Pulling out outer race for small tapered roller bearing
Pressing in. See Pressing in outer race for small tapered roller bearing

38 - Shim "S4"

39 - Pressure plate

40 - Rubber disc

Compensates length variations
To remove, insert self-tapping screw center and pull out washer on self-tapping screw.
Use components according to the transmission code letters. Refer to Code letters, application, ratios, capacities .

41 - Transmission cover

Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces