Shift Fork Group, Input Shaft, 1ST, 2ND And Reverse Gear Output Shafts, Installing On The Output Shaft: Notes

WARNING: This page is about a different car, the 2010 Audi A5. However, it is still accessible from the selected car via links, so may be relevant.

-- Install the plate T40213/1 with the adapters T40213/5 and T40213/6 on the V.A.G 1290 A table.

Fig 1: Install Plate T40213/1 With Adapters T40213/5 And T40213/6 On V.A.G 1290 A Table

Courtesy of AUDI OF AMERICA, LLC

-- Install the output shaft -1- and input shaft -2- in the adapter T40213/5 and T40213/6.

-- Install the bearing bracket over both shafts -3- ; the plastic part -4- faces upward.

Installation Position: 1st and 2nd Gear Synchronizer Rings

Fig 2: Installation Position Of Synchronizer Rings For 1St And 2Nd Gear

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Place inner race -2- on sliding gear -1-.

-- Install intermediate ring -3-. Tab -B- must be inserted into recess -A-.

-- Insert synchronizer ring -4-. Guide tabs -C- through recess -arrow-.

-- Install the 2nd gear wheel, the needle bearing and the synchronizer rings -A-. Place close attention to the position of the synchronizer rings, refer to INPUT SHAFT ASSEMBLY OVERVIEW .

Fig 3: Install 2Nd Gear Wheel, Needle Bearing And Synchronizer Rings -A-. Place Close Attention To Position Of Synchronizer Rings

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The tabs -arrows- on the synchronizer rings must fit into the openings on the synchronizer hub when installing the 1st/2nd gear synchronizer hub.

Installing the 1st/2nd Gear Synchronizer Hub

Fig 4: Installing 1St/2Nd Gear Synchronizer Hub

Courtesy of AUDI OF AMERICA, LLC

Heat the synchronizer hub to approximately 100 °C (212° F).
Synchronizer hub installed position: the higher inside collar is facing the 2nd gear wheel.

NOTE:

Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.

-- Install the 1st/2nd gear synchronizer hub locking ring.

When replacing the synchronizer hub or the output shaft:

Determine the locking ring -1- for the 1st/2nd gear synchronizer hub.

Fig 5: Determine Locking Ring -1- For 1St/2Nd Gear Synchronizer Hub

Courtesy of AUDI OF AMERICA, LLC

-- Determine thickest circlip which can still just be installed and insert it. For the part number.

The following locking rings are available:

Locking Ring Thickness (mm)
2.44	2.47	2.50

-- Install the 1st gear wheel, the synchronizer rings and the needle bearings on the output shaft.

-- Install the thrust washer -A- and then install the heated inner race -B- for the reverse gear needle bearing.

Fig 6: Install Thrust Washer -A- And Then Install Heated Inner Race -B- For Reverse Gear Needle Bearing

Courtesy of AUDI OF AMERICA, LLC

-- Install the reverse gear needle bearing, the gear wheel and the reverse gear locking collar INSTALLED POSITION: LOCKING COLLAR -2- AND REVERSE GEAR WHEEL -1- .

-- Install the reverse gear synchronizer ring in the locking collar.

-- Heat the reverse gear synchronizer hub to approximately 100 °C (212° F).