Input Shaft 1, Disassembling And Assembling

WARNING: This page is about a different car, the 2025 Audi A4 allroad and 2025 Audi A4 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Press Tool :T40323
Extracting Tool : T40413
Press Plate :VW402
Press Piece - Multiple Use :VW412
Seal Installer - Shaft Seal : T10431
Wishbone Rubber Mount Assembly Tool : T10219
Press Piece - Trailing Arm :2010
Press Piece - Front Control Arm :2040
Drive Sleeve :30-20

Disassembling

-- Remove the input shaft 1. Refer to INPUT SHAFT 1, REMOVING AND INSTALLING .

Sensor wheel, pressing off, if necessary

-- Insert the input shaft -1- with the sensor wheel -2- in the corresponding groove of the Press Plate :VW402 -3-.

Fig 1: Press off the sensor wheel -1-

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-- Press off the input shaft -1- downward.

Input shaft 1, pressing out

-- Press out input shaft 1.

Fig 2: Input shaft 1, pressing out

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2 - Thrust Piece 1 of the Seal Installer - Shaft Seal : T10431
3 - Thrust Piece 5 of the Press Tool : T40323
4 - Press Plate :VW402

Conditions

Secure the input shaft from falling when pressing out.
If not removed, make sure that the sensor wheel -1- is not damaged.

Assembling

-- Install the 5th gear assembly -1- with the synchronizer ring -2- and position the synchronizer hub -3- with the lettering facing upward.

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-- Install the bearing inner race while positioning the fluid holes -arrows- at an approximately 90° offset.

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-- Using the Wishbone Rubber Mount Assembly Tool :T10219 , press the bearing inner race -1- with the synchronizer hub -2- up to approximately two-thirds of the way on before the stop.

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Conditions

Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Wishbone Rubber Mount Assembly Tool.

-- Lift the 5th gear synchronizer ring with the 5th gear assembly -3- until the synchronizer ring anti-twist mechanism joins with the synchronizer hub cut-out -arrows-.

-- At the same time, install the bearing inner race -1- and synchronizer hub -2- until they stop.

-- Use the flywheel -1- as an assembly stand for input shaft 1 -2-.

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-- Insert thrust pieces -arrows-.

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-- Push the double-toothed locking collar onto the cut-out -arrow A- with the lettering facing upward.

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-- Press in the thrust piece balls on slightly by hand when pushing in.

-- Mount the synchronizer ring -1- with the 7th gear needle bearing -2- and 7th gear assembly -3-.

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-- Install the thrust washer -1- using the Wishbone Rubber Mount Assembly Tool :T10219 .

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Tip

Deposits on the thrust washer are not critical. Clean before installation, if necessary.

Sensor wheel, pressing on

If removed, press on the sensor wheel -6-.

-- Press on the sensor wheel -6- all the way.

Fig 3: Press on the sensor wheel -6-.

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Conditions

Installation position: The high collar faces the thrust piece 11 of the Extracting Tool : T40413
The dimension of the input shaft 1 is specified by the thrust piece 11 of the Extracting Tool : T40413 .

Press Piece - Multiple Use :VW412
Drive Sleeve :30-20
Press Piece - Trailing Arm :2010
Press Piece - Front Control Arm :2040
Thrust Piece 11 of the Extracting Tool : T40413