Output Shaft, Disassembling And Assembling

WARNING: This page is about a different car, the 2013 Audi S4, 2012 Audi S4, 2011 Audi S4, and 2010 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Press Plate VW401
Press Plate VW402
Press Piece - Multiple Use VW412
Press Piece - 60mm VW415A
Slide Hammer Set VW771
Seal Installer - Steering Rack 3013
Press Piece - Bushing 3118
Press Piece - Reverse Gear Syncro 3296
Shop Press VAG1290A
Inductive Heater VAS6414
-1- Puller - Kukko Internal - 12-16mm 21/1
-3- Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm Kukko 17/2

NOTE:

Removing and installing 1st, 2nd and reverse gears is described in. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING .

Remove the 3rd and 4th Gear Wheels, Roller Bearings and Inner Race/2nd Gear Wheel Needle Bearing from the Output Shaft.

-- Remove the 4th gear wheel locking ring.

Fig 1: Removing the 4th Gear Wheel

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NOTE:

Pressing force may be up to 200 kN (20 t).

Check the splines on the 4th gear wheel for damage after removing it.

Fig 2: Removing the 3rd Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Pressing force may be up to 200 kN (20 t).

Check the splines on the 3rd gear wheel for damage after removing it.

Fig 3: Identifying Roller Bearing With Inner Ring/Needle Bearing -D- For 2nd Gear And Thrust Washer -E- From Output Shaft

Courtesy of AUDI OF AMERICA, LLC

A -

Puller - Quick Action Separating Tool - 22-115mm Kukko 17/2, for example

NOTE:

Place the Separating Tool -A- underneath the bearing cage -B-.

Place bearing bracket -C- over roller bearing on output shaft so that the rollers are not pressed out of the bearing cage -B-.

The roller bearing cage can also get damaged when removing it with, for example, a screwdriver. Then mount the Separating Tool -A- on the inner race.

Install the 3rd and 4th Gear Wheels, Roller Bearings and Inner Race/2nd Gear Wheel Needle Bearing on the Output Shaft.

Fig 4: Identifying Roller Bearing On Output Shaft

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Installing Inner Race/Needle Bearing, 2nd Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

-- First fit the thrust washer -A- onto the roller bearing.

-- Next, heat the inner race/2nd gear wheel needle bearing up to approximately 100 °C (212 °F), and install all the way up to the stop.

WARNING:

Wear safety gloves.

Fig 6: Heat the 3rd Gear Wheel to a Maximum 150 Degrees C (302 Degrees F) and Install All the Way to the Stop

Courtesy of AUDI OF AMERICA, LLC

Installation position: The high inner collar -arrow- faces the 4th gear.

WARNING:

Wear safety gloves.

NOTE:

Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

Fig 7: Identifying 4th Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

Installation position: The high inner collar -arrow- faces the 3rd gear -A-.

WARNING:

Wear safety gloves.

NOTE:

Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

-- Install the 4th gear wheel locking ring.

Fig 8: Pulling Out Flange Shaft/Pinion Needle Bearing

Courtesy of AUDI OF AMERICA, LLC

A -

Internal Puller 12 to 14.5 mm 21/1, for example

Fig 9: Driving In Flange Shaft/Pinion Needle Bearing Flush

Courtesy of AUDI OF AMERICA, LLC

Install needle bearings with labeled side (thicker metal side) facing the Seal Installer - Steering Rack 3013.