Wheel Set, 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 Piece - Multiple Use VW412
Press Piece - 60mm VW415A
Press Piece - Multiple Use VW447H
Press Piece - Multiple Use 40-105
Press Piece - Reverse Gear Syncro 3296
Shop Press VAG1290A
Inductive Heater VAS6414
Gearbox Support T40206
Gearbox Assembly Tool T40213
-1- Puller - Kukko 2-Arm - 70-180mm 20/10
-2- 200 mm Pulling Hook

Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Removing

-- Secure the Gearbox Assembly Tool - Plate T40213/1 to the Gearbox Support T40206 using bolts -arrows-.

Fig 1: Locating Bolts To Attach Special Tools

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Gearbox Assembly Tool - Adapter T40213/6 and T40213/7 into the Gearbox Assembly Tool - Plate T40213/1.

NOTE:

Use Gearbox Assembly Tool - Knurled Bolt T40213/3 to mount the Adapter after installing the input and output shafts.

-- Install the input shaft -1- together with the output shaft -2- and the shift fork group -3- into the Gearbox Assembly Tool - Adapter T40213/6 and T40213/6.

Fig 2: Identifying Input & Output Shafts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and remove the shift fork group from the bearing bracket -4-.

-- Remove the thrust washer -A-, reverse gear synchronizer hub -B- and reverse gear wheel -C-.

Fig 3: Removing/Installing Thrust Washer And Gears

Courtesy of AUDI OF AMERICA, LLC

-- Remove the 1st gear wheel -E- along with the inner race/needle bearing for reverse gear -C- and the thrust washer -D-.

Fig 4: Removing 1st Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

A - Puller - 2-Arm - 70-180mm, z. B. 20/10

B - 200 mm Pulling Hook

CAUTION:

Danger of causing damage to the clutch splines on the 1st gear wheel -E-.

The hooks on the Two-Arm Puller must not touch the clutch splines on the 1st gear wheel when removing.

-- Remove the 2nd gear wheel -E- along with the inner race/needle bearing for 1st gear -C- and the synchronizer hub/locking collar -D-.

Fig 5: Removing 2nd Gear Wheel

Courtesy of AUDI OF AMERICA, LLC

A - Puller - 2-Arm - 70-180mm, z. B. 20/10

B - 200 mm Pulling Hook

-- Remove the needle bearing -1-.

Fig 6: Removing Needle Bearing

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bearing bracket -2- from the input -4- and output shafts -3-.

NOTE:

Output Shaft, Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

Input Shaft, disassembling and assembling. Refer to INPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Installing on the Output Shaft

-- Place the Gearbox Assembly Tool - Plate T40213/1 with the Gearbox Assembly Tool - Adapters T40213/6 and T40213/7 on the Shop Press VAG1290A pressing table.

Fig 7: Locating Raised Surfaces

Courtesy of AUDI OF AMERICA, LLC

-- Position the output shaft -1- and input shaft -2- into the Gearbox Assembly Tool - Adapter T40213/6 and T40213/7

-- In the installed position, mount the bearing bracket over both shafts -3-, and the raised surfaces -arrows- face upward.

Fig 8: Identifying Installation Position Of Synchronizer Rings For 1st And 2nd Gear

Courtesy of AUDI OF AMERICA, LLC

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

-- Insert 2nd gear wheel together with needle bearing and synchronizer rings.

Fig 9: Installing Synchronizer Hub With Locking Collar For 1st And 2nd Gears

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Heat the synchronizer hub to approximately 100°C (212°F).

Note the locking collar/synchronizer hub installed location; refer to Figure.

Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.

Fig 10: Heat Inner Race/Needle Bearing -A- For 1st Gear Wheel Up To Approximately 100 Degrees C (212 Degrees F) And Install

Courtesy of AUDI OF AMERICA, LLC

-- Install the 1st gear wheel -A-, the synchronizer rings and the needle bearings on the output shaft.

Fig 11: Identifying 1st Gear Wheel On Output Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Mount the thrust washer -B- and install the heated inner race -C- for the needle bearing reverse gear wheel.

-- Mount the reverse gear wheel -C- with needle bearing and reverse gear locking collar.

Fig 12: Removing/Installing Thrust Washer And Gears

Courtesy of AUDI OF AMERICA, LLC

-- Mount the reverse gear synchronizer hub -B- along with the synchronizer rings and thrust washer -A-.

-- Attach the Gearbox Assembly Tool - Plate T40213/1 to the Gearbox Support T40206.

Fig 13: Identifying Input & Output Shafts

Courtesy of AUDI OF AMERICA, LLC

-- Clean screw threads -arrows- with a wire brush. Coat the bolts with Locking Fluid AMV 185 101 A1.

-- Secure the shift fork group -3- to the bearing bracket -4- with the bolts -arrows-.

-- Remove the input shaft -1- together with the output shaft -2- and shift fork group from the Gearbox Assembly Tool - Plate T40213/1