Checking Synchronizer Ring For Wear

-- Press the synchronizer ring -E- into the locking collar and then measure the gap dimension -a- using a depth gauge -D- at -A-, -B- and -C-.

Fig 1: Checking Synchronizer Ring For Wear

Courtesy of AUDI OF AMERICA, LLC

-- Add measured values and divide by 3.

Determined value must not exceed 0.5 mm.

-- Install the roller bearing all the way onto the input shaft.

Fig 2: Installing Roller Bearing Onto Input Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Carefully expand the new locking ring -1- guide it over the splines on the 5th/6th gear synchronizer hub -3-.

Fig 3: Expanding New Locking Ring Guide Over Splines On 5th/6th Gear Synchronizer Hub

Courtesy of AUDI OF AMERICA, LLC

• The locking ring must not be turned by hand in the groove all around the input shaft

-- Expand the needle bearing -2- on the 5th gear wheel and carefully guide id over the locking ring -1-. When doing this, do not lay the needle bearing on the collar -arrow- on the input shaft.

-- Install the 5th gear wheel -B-.

Fig 4: Installing 5Th Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

• The gear wheel -B- must not touch the locking ring -A- while it is being turned.
• There must be an even distance -x- between the gear wheel and the locking ring.

-- Install the 5th gear synchronizer ring.