Output Shaft

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Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Thrust Disc VW 412
Tube 60 mm Dia. VW 415 A
Slide Hammer-Complete Set VW 771
Seal Driver 3013
Press Support 3118
Tube 3296
Shop Press V.A.G 1290A
Inductive Heater VAS 6414
-1- Internal Puller Kukko 21/1
-3- Separating Tool 22 to 115 mm, for example, Kukko 17/2

NOTE:

Removing and installing 1st, 2nd and reverse gears. Refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS .

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: Remove the Roller Bearing with Inner Ring/Needle Bearing -D- for 2nd Gear and Thrust Washer -E- from the Output Shaft

Courtesy of AUDI OF AMERICA, LLC

A - Separating tool 22 to 115 mm, for example, Kukko 17/2

NOTE:

Place the separating tool -A- underneath the housing -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 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: Installing Roller Bearing On Output Shaft

Courtesy of AUDI OF AMERICA, LLC

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

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 °C (302 °F) and Install All the Way to the Stop

Courtesy of AUDI OF AMERICA, LLC

Installed 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: Removing 4th Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

Installed position: The high inner collar -arrow- points to 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, for example, Kukko 21/1

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

Courtesy of AUDI OF AMERICA, LLC

Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards 3013.