Input 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 - Rod VW407
Press Piece - Rod VW408A
Press Piece - Multiple Use VW412
Press Piece - Multiple Use VW454
Press Piece - 60mm VW415A
Press Piece - Front Control Arm 2040
Press Piece - Bushing 3118
Press Piece - Reverse Gear Syncro 3296
Gearbox Assembly Tool T40213
Shop Press VAG1290A
Inductive Heater VAS6414
-3- Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm Kukko 17/2
Feeler Gauge

Input Shaft, Disassembling

The input shaft is removed from the output shaft and the bearing bracket. Refer to OVERVIEW - WHEEL SET .

-- With the Drive Axle removed, you will first have to remove the circlip -A- and the shim -B- behind the ball bearing.

Fig 1: Identifying Locking Ring And Shim

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-- Place the Separating Tool -A- underneath the helical-cut gear teeth on the 4th gear wheel and remove the ball bearing by pressing on it.

Fig 2: Removing Ball Bearing

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A -

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

-- Remove the synchronizer ring, needle bearing for the 4th gear selector wheel.

-- Place the Separating Tool -A- underneath the helical-cut gear teeth on the 6th-gear wheel and remove the synchronizer hub in the 3rd/4th gear together with the inner race/needle bearings for the 3rd- and 4th-gear wheels.

Fig 3: Removing Synchronizer Hub

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A -

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

-- Remove the synchronizer rings and needle bearing(s) for the 6th-gear selector wheel.

-- Remove the 5th gear wheel, the 5th- and 6th-gear synchronizer hubs and the inner race/needle bearing for the 6th gear wheel by pressing on them.

Fig 4: Removing 5th And 6th Gear Components

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-- Press roller bearing off input shaft.

Fig 5: Removing Roller Bearing

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A -

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

NOTE:

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

Place bearing bracket -C- over roller bearing on input 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.

Input Shaft, Assembling

NOTE:

Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.

Before pressing needle bearing inner races off, warm to a maximum of 100 °C (212 °F) while wearing protective gloves.

Warm synchronizer ring before pressing off to a maximum of 100 °C (212 °F) while wearing protective gloves.

Always press roller bearing, needle bearing inner races and synchronizer body to stop so that selector gears have the recommended axial clearance.

Fig 6: Checking Synchronizer Ring For Wear

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-- Check inner race on outer friction surface arrow for scoring or signs of wear; replace if necessary.

-- 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 >>screw in<<.

NOTE:

>>Turn<< means: turn the synchronizer rings just about one turn while pressing on the rings at the same time.

-- Then measure the gap dimension -a- with a Feeler Gauge.

Gap dimension -a-	Wear limit
3rd to 6th gears	0.7 mm

NOTE:

Replace inner race, intermediate ring and synchronizer ring for the respective gear together.

Fig 7: Identifying Installation Position Of Synchronizer Rings For 1st And 2nd Gear

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NOTE:

If the parts are not to be replaced, make sure they are reallocated to their original gear.

-- Place inner race -2- on selector gear -1-.

-- Install the intermediate ring -3-. The tab -B- must be inserted into the recess -A-.

-- Insert the synchronizer ring -4-. Guide the tabs -C- through the recess -arrow-.

Note the Following When Performing the Next Steps:

-- Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).

-- After pressing briefly on components, stop and align pressing tool again at center and press to stop.

When pressing on, synchronizer ring tabs and synchronizer hub recesses must align. Raise the gear wheel with the synchronizer ring a little bit so that it locks into the openings on the synchronizer hub.

-- Set the Gearbox Assembly Tool - Plate T40213/1 with the Gearbox Assembly Tool - Adapter T40213/9 on the Shop Press VAG1290A pressing table.

Fig 8: Installing Driveshaft

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-- Set the input shaft in the Gearbox Assembly Tool - Adapter T40213/9.

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

-- Insert 5th gear selector gear together with needle bearing and synchronizer ring.

Fig 9: Assembly Of Locking Collar/Synchronizer Hub For 5th And 6th Gear

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-- Slide locking collar -1- over synchronizer hub -2-.

The openings -arrow C- for the thrust pieces -3- in the synchronizer hub and the notches -arrow D- in locking collar must be centered over one another.
Installation position: The higher inner collar -arrow C- or the notch -arrow D- on the synchronizer hub must face the 5th gear wheel.

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

Fig 10: Pressing On Synchronizer Hub With Locking Collar For 5th And 6th Gears

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Fig 11: Installing the 6th Gear Wheel Inner Race/Needle Bearing -A-

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-- Insert 6th gear selector gear -A- together with needle bearing and synchronizer rings.

Fig 12: Installing 6th Gear Selector Gear

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-- Place the thrust washer -B- on the 6th gear wheel.

-- Inner race/needle bearing; refer to -C- for the 3rd gear, pressing on.

-- Insert 3rd gear selector gear together with needle bearing and synchronizer rings.

Fig 13: Identifying Locking Pieces -A- In Locking Collar

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-- Coat the 3 locking pieces -A- with some grease on convex side -arrow 1-.

-- Insert 3 locking pieces with the convex side in the openings in the locking collar.

Fig 14: Assembly of Locking Collar/Synchronizer Hub for 3rd and 4th Gear

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Install the 3 locking pieces -4- in the installed position into the locking collar openings -1- ; refer to Fig 13.
Synchronizer hub installation position: The notch -arrow B- or the "label" must point towards the 4th gear wheel.

-- Place the locking collar -1- over the synchronizer hub -2- so that the openings on the synchronizer hub -arrow A- are centered over the installed locking pieces in the locking collar.

Fig 15: Identifying Synchronizer Hub With Locking Collar For 3rd And 4th Gears

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

Fig 16: Identifying Inner Race/Needle Bearing For 4th Gear Selector Gear, Pressing On

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-- Insert the 4th gear wheel -A- and the needle bearing and synchronizer rings.

Fig 17: Inserting 4th Gear Wheel

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-- Install the thrust washer -B-.

Check to make sure that the inner race/needle bearing -D- for the 4th gear wheel is higher than the 4th gear wheel itself -A-.

Press on the ball bearing -C- until it hits the end stop.

-- Then check all selector gears for ease of movement and axial play.

Gear wheel axial play must be at least 0.15 mm.

Determine Shim Thickness -B- as Follows:

Fig 18: Identifying Locking Ring And Shim

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-- Select the thickest, but still installable, shim from those available as replacement parts -B-.

After you have selected the shim, the locking ring -A- must lie against the groove.