Pinion shaft and hollow 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:

When installing new gear wheels or the final drive set consult technical data → Transmission identification .
Observe technical data when installing new gear wheels
Lubricate all needle bearings on hollow 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 And Hollow Shaft, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transmission housing ¹⁾

2 - Shim "S3"

Table of adjustments → Table of adjustments

3 - Double tapered roller bearing outer race ¹⁾

4 - Pinion shaft ¹⁾

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

5 - Double tapered roller bearing inner race ¹⁾

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

6 - Circlip

Redetermine thickness if double tapered roller bearing is replaced Determining thickness of circlip

7 - Large needle bearing

For pinion shaft in hollow shaft
Lubricate with gear oil

8 - Hollow shaft

Disassembling and assembling

9 - Small needle bearing

For pinion shaft in hollow shaft
Lubricate with gear oil

10 - Large needle bearing for 1st gear

11 - Small needle bearing for 1st gear

12 - 1st speed selector gear

Check axial clearance after installing using feeler gauge Checking axial play of selector gears (0.20 to 0.50 mm)

13 - 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

14 - 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

15 - 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

16 - 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

17 - Locking piece

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

18 - 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

19 - Circlip

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

20 - Needle bearing

For 2nd gear

21 - 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

22 - 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

23 - 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

24 - 2nd speed selector gear

Check axial clearance after installing using feeler gauge Checking axial play of selector gears (0.20 to 0.50 mm)

25 - Circlip

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

26 - 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

27 - Circlip

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

28 - 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

29 - 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

30 - Shim "S₄ "

Table of adjustments → Table of adjustments

31 - Bearing housing ¹⁾

32 - Needle bearing

For reverse selector gear

33 - Reverse selector gear

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

34 - Spring

Insert into reverse selector gear Inserting spring in selector gear

35 - Synchronizing ring for reverse gear

Checking for wear Checking synchro-ring for wear

36 - Reverse gear synchronizing hub

Installation position: high inside collar faces 3rd gear wheel

37 - Reverse gear locking collar

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

38 - 3rd gear wheel

Installation position: machined side faces reverse gear synchronizing hub

39 - Circlip

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

40 - 4th gear wheel

Installation position: high inside collar faces 5th gear wheel

41 - 5th gear wheel

Installation position: high inside collar faces 4th gear wheel

42 - Spacer sleeve

43 - 6th gear wheel

44 - 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 the hollow shaft Determining thickness of circlip

45 - Needle bearing

Bearing for hollow shaft in transmission cover

46 - Multi-point socket head bolt, 24Nm

47 - Retaining plate

48 - Transmission cover