Output Shaft Overview

Shift fork group, input shaft, 1st, 2nd and reverse gear output shafts, removing and installing, refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS OVERVIEW .

Assembly sequence - remove and install the shift fork group, driveshaft, first, second and reverse gears on the output shaft; refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS .

Output shaft, disassembling and assembling, refer to OUTPUT SHAFT .

Fig 1: Identifying Output Shaft Overview

Courtesy of AUDI OF AMERICA, LLC

1. Transmission Housing
2. Ball Bearing
   • For the output shaft
   • Replace TRANSMISSION HOUSING => List Item:Ball Bearing
3. Plate
   • To lock the ball bearing in the transmission housing on
4. Thrust Washer
5. Reverse Gear Synchronizer Hub
   • Can be manually removed from the output shaft
6. Reverse Gear Inner Race
   • Installed position, refer to Figure
   • Differentiating the spring pins; refer to Fig 3
   • Replace if there are grooves or scoring
7. Reverse Gear Intermediate Ring
   • Installed position, refer to Figure
   • Differentiating the spring pins, refer to Fig 3
   • Checking for wear, refer to Fig 6
8. Synchronizer Ring for Reverse Gear
   • Installed position, refer to Figure
   • Differentiating the spring pins, refer to Fig 3
   • Checking for wear, refer to Fig 6
   • Replace if there are grooves or scoring
9. Reverse Gear Wheel
   • With reverse gear locking collar
   • Locking collar and reverse gear selector gear, disassembling and assembling, refer to Fig 2
10. Bolt
    • Tightening specification TRANSMISSION HOUSING => List Item:Bolt
11. Needle Bearing
    • For reverse gear
12. Inner Race/Needle Bearing
    • For reverse gear
    • Removing, refer to Figure
    • Installing, refer to Figure
13. Thrust Washer
    • For 1st gear and reverse gear selector gears
14. 1st Gear Wheel
15. 1st Gear Inner Race
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Checking for wear, refer to Fig 5
    • Replace if there are grooves or scoring
16. Intermediate Ring for 1st Gear
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Checking for wear, refer to Fig 6
17. Synchronizer Ring for 1st Gear
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Identification, refer to Fig 4
    • Checking for wear, refer to Fig 6
    • Replace if there are grooves or scoring
18. Needle Bearing
    • For 1st gear
19. Inner Race/Needle Bearing
    • For the 1st gear selector gear
    • Removing, refer to Figure
    • Installing, refer to Figure
20. Locking Collar/Synchronizer Hub for 1st and 2nd Gears
    • Assembling locking collar/synchronizer hub, refer to Fig 7
    • Removing, refer to Figure
    • Installing, refer to Figure
21. 2nd Gear Synchronizer Ring
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Identification, refer to Fig 4
    • Checking for wear, refer to Fig 6
    • Replace if there are grooves or scoring
22. Intermediate Ring for 2nd Gear
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Checking for wear, refer to Fig 6
23. 2nd Gear Inner Race
    • Installed position, refer to Figure
    • Differentiating the spring pins, refer to Fig 3
    • Checking for wear, refer to Fig 5
    • Replace if there are grooves or scoring
24. 2nd Gear Wheel
25. Needle Bearing
    • For 2nd gear
26. Inner Race/Needle Bearing
    • For selector gear of 2nd gear
    • Removing, refer to Figure
    • Installing, refer to Figure
27. Thrust Washer
    • For selector gear of 2nd gear
28. Bearing Bracket
    • Supports input shaft and input shaft in transmission cover
    • Refer to item 3 in Figure
29. Roller Bearing
    • For the output shaft
    • Removing, refer to Figure
    • Installing, refer to Figure
30. Output Shaft
    • With splines for 5th and 6th gears
31. Needle Bearing
    • For the rear flange shaft bearing in the output shaft
    • Removing, refer to Figure
    • Installing, refer to Figure
32. 3rd Gear Wheel
    • Removing, refer to Figure
    • Installed position: High inner collar faces 4th gear
    • Installing, refer to Figure
33. 4th Gear Wheel
    • Removing, refer to Figure
    • Installed position: High inner collar faces the 3rd gear
    • Installing, refer to Figure
34. Locking Ring
35. Transmission Cover
36. Output Wheel/Drive Wheel
    • With tapered roller bearing and gear carrier
    • Spur gear bearing, servicing, refer to SPUR GEAR AND CENTER DIFFERENTIAL BEARING 

Fig 2: Assembling Locking Collar And Reverse Gear Selector Gear

Courtesy of AUDI OF AMERICA, LLC

1. Reverse gear wheel
2. Locking collar
3. Thrust piece

-- Slide locking collar over reverse gear selector gear.

Installed position:

• The pointed gear teeth -arrow A- on the locking collar and the helical-cut gear teeth -arrow B- on the reverse gear wheel will face the opposite direction after being assembled.
• Thrust piece notches -3- on the reverse gear wheel -arrow C- and locking collar -arrow D- must be centered over each other.

-- Next, place the thrust pieces -3- in reverse gear selector gear notches and press the thrust pieces into the locking collar notches -arrow D-.

Fig 3: Differentiation Of Reverse Gear Synchronization Rings And 1st/2nd Gear

Courtesy of AUDI OF AMERICA, LLC

1. Synchronizer ring for reverse gear: tabs -arrow 1- have a smooth surface.
2. Reverse gear intermediate ring: friction surfaces -arrow 2- are coated with sintered linings (brass colored).
3. Reverse gear inner race: has no inner friction surface -arrow 3-.
4. Synchronizer ring for 1st and 2nd gear: tabs have 2 ridges each -arrow 4-. Identification for the 1st and 2nd gear synchronizer ring; refer to Fig 4.
5. Intermediate ring for 1st and 2nd gear: The friction surfaces -arrows 5- are coated with carbon (black).
6. Inner race for 1st and 2nd gear: The inner race -arrow 6- is coated with carbon (black).

Fig 4: Identifying Identification For 1st And 2nd Gear Synchronizer Ring

Courtesy of AUDI OF AMERICA, LLC

1. Synchronizer ring for 1st gear: The identifying label of "19100" -arrow 1- means that the clutch spline's angle (∠) is 19°.
2. Synchronizer ring for 2nd gear: The identifying label of "17101" -arrow 2- means that the clutch spline's angle (∠) is 17°. Also, in each case, 3 x 3 gear teeth are missing on this synchronizer ring -arrows 3-.

Fig 5: Checking Inner Race Of 1st Gear For Wear

Courtesy of AUDI OF AMERICA, LLC

-- Check the outer friction surface -arrow- for scoring or signs of wear, replace if necessary.

-- Press inner race onto taper of selector gear and measure gap dimension -a- using a feeler gauge.

Fig 6: Checking Synchronizer Ring For Wear

Courtesy of AUDI OF AMERICA, LLC

-- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.

-- Place inner race, intermediate ring and synchronizer ring on selector gear taper and turn.

-- Then measure the gap dimension -a- with a feeler gauge.

Fig 7: Identifying Assembly Of Locking Collar/Synchronizer Hub For 1st And 2nd Gears

Courtesy of AUDI OF AMERICA, LLC

-- Mount the locking collar -1- over the synchronizer hub -2- so that the wire tooth spacing on the locking collar -arrow A- and on the synchronizer hub -arrow B- align with each other.

• Locking collar installed position: The bevel -arrow C- or the side with the greater outside diameter faces the 2nd gear wheel.
• Installed position of synchronizer hub: The notch -arrow D- or the "labeling" must face the 2nd gear wheel.

-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrow E- in the locking collar.