3rd to 6th gear, removing and installing

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:

3rd to 6th speed selector gears should have an axial play of 0.20to0.50mm after installing.

Fig 1: 3rd To 6th Gear Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bearing housing

2 - Oil collector

With magnet
Clipped into reverse shaft support.

3 - Circlip

Install thickest circlip that will still just fit.
Re-determining thickness → Disassembling and assembling sequence

4 - 6th gear wheel

5 - Spacer sleeve

6 - 5th gear wheel

Installation position: high inside collar faces 4th gear wheel

7 - 4th gear wheel

Installation position: high inside collar faces 5th gear wheel

8 - 3rd gear wheel

Detach bearing housing from transmission housing and remove pinion shaft prior to removing and installing → Disassembling and assembling sequence

9 - Thrust washer

For 3rd speed selector gear

10 - Needle bearing

For 3rd gear

11 - 3rd speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

12 - 3rd gear synchro-ring

Checking for wear Checking synchro-ring for wear

13 - Circlip

Mark

14 - Synchronizing hub for 3rd and 4th gear

Installation position: high inside collar faces 3rd speed selector gear

15 - Circlip

Re-determining thickness → Disassembling and assembling sequence

16 - Locking collar for 3rd and 4th gear

Mark position in relation to synchronizing hub prior to removing

17 - Pin with clip

For securing selector fork for 3rd and 4th gear to selector rod

18 - Selector fork for 3rd and 4th gear

19 - 4th gear synchro-ring

Checking for wear Checking synchro-ring for wear

20 - 4th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

21 - Needle bearing

For 4th gear

22 - Thrust washer

For 4th speed and 5th speed selector gears

23 - Needle bearing inner race

For 5th gear

24 - Needle bearing

For 5th gear

25 - 5th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

26 - 5th gear synchro-ring

Checking for wear Checking synchro-ring for wear

27 - Synchronizing hub for 5th and 6th gear

28 - Locking collar for 5th and 6th gear

Mark position in relation to synchronizing hub prior to removing

29 - Needle bearing inner race

For 6th gear

30 - Needle bearing

For 6th gear

31 - 6th gear synchro-ring

Checking for wear Checking synchro-ring for wear

32 - 6th speed selector gear

Insert spring before installing Inserting spring in selector gear
Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

33 - Thrust washer

For 6th speed selector gear

34 - Inner race

For needle roller bearing

35 - Multi-point socket head bolt, 150Nm

36 - Pin with clip

For securing selector fork for 5th and 6th gear to selector rod

37 - Selector fork for 5th and 6th gear