Drive pinion and hollow shaft, assembly overview

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2007 Audi S4, 2007 Audi RS 4, and 2006 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Drive pinion, disassembling and assembling → Drive pinion, disassembling and assembling

Hollow shaft, disassembling and assembling → Hollow shaft, disassembling and assembling

NOTE:

When installing new gears or gear set, note technical data → 00 TECHNICAL DATA .
Insert all needle bearings and synchronizer rings with transmission fluid.
When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear. Do not interchange reverse gear synchronizer rings with 1st and 2nd gear synchronizer rings → Differentiation of reverse gear synchronization rings and 1st/2nd gear .
Items 22 to 29, 32 and 49 were changed in the version with selector rod for 1st/2nd gear with spring-loaded shift fork → 1st/2nd gear selector rod with spring-loaded shift fork .
Adjustments are required when replacing components marked with ¹⁾ . List of adjustments → Adjustment overview .

Fig 1: Drive Pinion And Hollow Shaft, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transmission housing ¹⁾

2 - Adjustment shim " S ₃ "

Adjustment overview → Adjustment overview

3 - Drive pinion ¹⁾

Is mated with ring gear, always replace together as a set
Disassembling and assembling → Drive pinion, disassembling and assembling
Drive pinion and ring gear, adjusting → Pinion and ring gear, adjusting

4 - Needle bearing

For flange shaft mounting in drive pinion
Pulling out Flange shaft mounting needle bearing, removing from drive pinion
Driving in Flange shaft mounting needle bearing, driving in flush in drive pinion

5 - Double angular contact ball bearing

No adjustment is needed if only this bearing is replaced
Pressing off Double angular contact ball bearing, pressing off
Pressing on Double angular contact ball bearing, pressing on
Installation position: shoulder on outer race faces toward pinion face

6 - Adjustment shim " S ₅ "

Determine thickness → Shim " S 5 " for positioning inner race/tapered ball bearing, redetermining

7 - Tapered roller bearing inner race

Pressing off Pressing off inner race/tapered roller bearing
Pressing on Pressing on inner race/tapered roller bearing

8 - Washer

9 - Circlip

Determine thickness

10 - Needle bearing

For drive pinion in hollow shaft
Coat with transmission fluid

11 - Adjustment shim " S ₄ "

Adjustment overview → Adjustment overview

12 - Holding plate

Installation position: sanded side faces toward transmission housing, fits only in one position

13 - Bolt, 30 Nm

Qty. 6
Insert with locking fluid AMV 185 101 A1

14 - Hollow shaft

With 3rd and 4th gears
Disassembling and assembling → Hollow shaft, disassembling and assembling

15 - Drive gear for 6th gear

Pressing off 6th gear selector gear, pressing off
Pressing on 6th gear drive gear, pressing on
Installation position: High inner collar faces 5th gear drive gear

16 - Drive gear for 5th gear

Pressing off Pressing off 5th-gear gear wheel
Pressing on Pressing on 5th-gear gear wheel
Installation position: High inner collar faces 6th gear drive gear

17 - Roller bearing

For hollow shaft
Do not exchange with input shaft roller bearing
Press off together with drive gear for 5th gear Pressing off 5th-gear gear wheel
Pressing on Hollow shaft roller bearing, pressing on

18 - Bearing bracket

Roller bearing outer race must not have any radial play in bearing bracket.

19 - Adjustment shim " S ₆ "

For positioning 2nd gear selector gear
Determine thickness → Shim " S 6 " for positioning 2nd gear selector gear, redetermining

20 - Inner race/needle bearing

For selector gear of 2nd gear
Press off together with drive gear for 5th gear Pressing off 5th-gear gear wheel
Pressing on Inner race/needle bearing for 2nd gear selector gear, pressing on

21 - Needle bearing

For 2nd gear

22 - Selector gear for 2nd gear

23 - Inner race for 2nd gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
Replace if grooved or scored

24 - Intermediate ring for 2nd gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear

25 - Synchronizer ring for 2nd gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
Replace if grooved or scored

26 - Locking sleeve with synchronizer hub for 1st and 2nd gears

Removing and installing → Assembly sequence
Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 1st and 2nd gear

27 - Synchronizer ring for 1st gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
Replace if grooved or scored

28 - Intermediate ring for 1st gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear

29 - Inner race for 1st gear

Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
Replace if grooved or scored

30 - Inner race/needle bearing

For 1st gear selector gear

31 - Needle bearing

For 1st gear

32 - Drive gear for 1st gear

33 - Thrust washer

For 1st gear and reverse gear selector gears

34 - Gear wheel for reverse gear

With reverse gear locking collar
Removing and installing → Assembly sequence
Locking collar and reverse gear selector gear, disassembling and assembling Assemble locking collar and reverse gear selector gear

35 - Synchronizer ring for reverse gear