Pinion shaft, assembly overview: Notes

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 → Code letters, allocation, transmission ratios, capacities when installing new gear wheels or the final drive gear set.
Refer to technical data when installing new gear wheels
Lubricate all needle bearings on output shaft with gear oil before installing.
Adjustment work is required when replacing the parts marked with ¹⁾ . Table of adjustments → Table of adjustments

Fig 1: Pinion Shaft, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transmission housing ¹⁾

Servicing → Transmission housing, servicing

2 - Shim "S3"

Table of adjustments → Table of adjustments

3 - Tapered roller bearing outer race ¹⁾

4 - Pinion shaft (output shaft) ¹⁾

Is mated with crown wheel, always replace together as a set
Adjusting crown wheel and pinion shaft → → Pinion shaft and crown wheel, adjusting

5 - Tapered roller bearing inner race¹⁾

Will be damaged during removal
Replace
Pressing off Pressing off tapered roller bearing inner race
Pressing on Pressing on tapered roller bearing inner race

6 - Circlip

Re-determine thickness if taper roller bearing is replaced Determining thickness of circlip

7 - Needle bearing

For 1st gear

8 - 1st speed selector gear

Check axial clearance after installing using feeler gauge Checking axial play of 1st speed selector gear (0.20 to 0.50 mm)

9 - Inner ring for 1st gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st gear inner ring for wear
Replace if scored or if there are visible traces of wear

10 - Intermediate ring for 1st gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st and 2nd gear intermediate ring for wear

11 - Synchro-ring for 1st gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st and 2nd gear intermediate ring for wear
Replace if scored or if there are visible traces of wear

12 - Locking collar for 1st and 2nd gear

Mark position in relation to synchronizing hub prior to removing
Assembling locking collar/synchronizing hub Assembling 1st and 2nd gear locking collar/synchronizing hub

13 - Locking piece

Install locking pieces (3 Qty.) Assembling 1st and 2nd gear locking collar/synchronizing hub

14 - Synchronizing hub for 1st and 2nd gear

Installation position: high inside collar faces 2nd speed selector gear
Pressing off Pressing off 1st and 2nd gear synchronizing hub
Pressing on Pressing on 1st and 2nd gear synchronizing hub
Assembling locking collar/synchronizing hub Assembling 1st and 2nd gear locking collar/synchronizing hub

15 - Circlip

Mark
Installation position Installation position of circlips , - item 1 -
Re-determine thickness when replacing 1st and 2nd gear synchronizing hub or pinion shaft Determining thickness of circlip

16 - Needle bearing

For 2nd gear

17 - Synchro-ring for 2nd gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st and 2nd gear intermediate ring for wear
Replace if scored or if there are visible traces of wear

18 - Intermediate ring for 2nd gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st and 2nd gear intermediate ring for wear

19 - Inner ring for 2nd gear

Installation position Installation position of synchronizing rings for 1st and 2nd gear:
Checking for wear Checking 1st and 2nd gear intermediate ring for wear
Replace if scored or if there are visible traces of wear

20 - 2nd speed selector gear

Check axial clearance after installing using feeler gauge Checking axial play of 2nd speed selector gear (0.20 to 0.50 mm)

21 - Circlip

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

22 - Tapered roller bearing inner race¹⁾

Pressing off Pressing off tapered roller bearing inner race with 2nd speed selector gear
Pressing on Pressing on tapered roller bearing inner race

23 - Circlip

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

24 - Thrust washer

For reverse selector gear
Pressing off Pressing off thrust washer for reverse selector gear
Pressing on Pressing on thrust washer for reverse selector gear

25 - Tapered roller bearing outer race ¹⁾

Pulling out Pulling tapered roller bearing outer race out of bearing housing
Pressing in Pressing tapered roller bearing outer race into bearing housing

26 - Shim "S₄ "

Table of adjustments → Table of adjustments

27 - Bearing housing ¹⁾

28 - Needle bearing

For reverse selector gear

29 - Reverse selector gear

Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

30 - Spring

Insert into reverse selector gear Inserting spring in selector gear
Allocation of spring to selector gear

31 - Synchronizing ring for reverse gear

Checking for wear Checking synchro-ring for wear

32 - Reverse gear synchronizing hub

Installation position: high inside collar faces 3rd gear wheel

33 - Reverse gear locking collar

Mark position in relation to synchronizing hub prior to removing
Installation position: taper faces reverse gear synchro-ring

34 - 3rd gear wheel

Installation position: machined side faces reverse gear synchronizing hub

35 - Circlip

Mark
Installation position Installation position of circlips , - item 4 -
Re-determine thickness when replacing 3rd gear wheel, reverse gear synchronizing hub or pinion shaft Determining thickness of circlip

36 - 4th gear wheel

Installation position: high inside collar faces 5th gear wheel

37 - 5th gear wheel

Installation position: high inside collar faces 4th gear wheel

38 - Spacer sleeve

39 - 6th gear wheel

40 - Circlip

Mark
Installation position Installation position of circlips , - item 5 -
Re-determine thickness when replacing gear wheels for 4th to 6th gear, the spacer sleeve or pinion shaft Determining thickness of circlip

41 - Needle bearing

Bearing for pinion shaft in transmission cover

42 - Multi-point socket head bolt, 24Nm

43 - Retaining plate

44 - Transmission cover