Input Shaft 2, 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

Puller - Transmission Gears :T10309A
Extracting Tool : T40413
Press Plate :VW401
Press Plate :VW402
Press Piece - Multiple Use :VW447H
Press Piece - Multiple Use :VW412
Bearing Installer - Needle Bearing :30-506B
Inductive Heater :VAS 6414
Press Piece - 60mm :VW415A
Drive Sleeve :30-20

Disassembling

-- Remove the input shaft 2. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .

Sensor wheel for input shaft 2, removing

-- Remove the sensor wheel -1-. The half shells -2- of the Puller - Transmission Gears : T10309A cannot be closed completely.

Fig 1: Remove the Sensor Wheel -1- for the Input Shaft 2

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3 - Puller - Transmission Gears :T10309A
4 - Press Piece - Multiple Use :VW447H

Input shaft 2, pressing off

-- Remove the circlip -2-.

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-- Remove the thrust washer -1- and 4th gear assembly -3- with the needle bearing.

-- Press off input shaft 2 -1-. The other components remain on the Pressure Plate : VW401A and must be secured from falling.

Fig 2: Input Shaft 2 -1-, Pressing on

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-- When removing the remaining components in the sequence, at the same time pay attention to the installation position.

2 - Press Piece - Multiple Use :VW412
3 - Drive Sleeve :30-20
4 - Bearing Installer - Needle Bearing :30-506B
5 - Press Plate :VW401

Assembling

6th gear assembly inner race, installing

-- Push on the thrust washer -2-.

Fig 3: 6th Gear Wheel Inner Race -1-, Installing

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-- Warm up the inner race -1- using the Inductive Heater : VAS 6414 to approximately 100°.

-- Install the inner race -1- using the Press Piece - 60mm : VW415A -3- and Press Piece - Multiple Use : VW412 .

Conditions

Layout of the oil filler hole -arrows- at an offset of approximately 90°.
Pay attention to the installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - 60mm :VW415A .

-- Press on the needle bearing for the 6th gear assembly -1-, 6th gear assembly -2- and synchronizer ring for 6th gear assembly -3-.

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Synchronizer hub, installing

-- Lift the 6th synchronizer ring -2- with 6th gear assembly -3- slightly, until the anti-twist mechanism -arrow B- of the synchronizer ring is flush with the cut-outs -arrow A- of the synchronizer hub -1-.

Fig 4: Synchronizer Hub -1-, Pressing On

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-- Warm up the synchronizer hub -1- using the Inductive Heater : VAS 6414 to approximately 100 °C (212 °F).

-- Press on the synchronizer hub -1- using the Press Piece - 60mm : VW415A .

Conditions

Pay attention to the installation position: The lettered side of the synchronizer hub points to the Press Piece - 60mm : VW415A .

-- 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 the tops of the thrust pieces in slightly by hand when installing.

4th gear assembly inner race, installing

-- Warm up the inner race -1- using the Inductive Heater : VAS 6414 to approximately 100°.

Fig 5: Inner Race for 4th Gear Selector Gear -1-, Pressing On

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-- Install the inner race -1- using the Press Piece - 60mm : VW415A -3- and Press Piece - Multiple Use : VW412 .

Conditions

Layout of the oil filler hole -arrows- at an offset of approximately 90°.
Pay attention to the installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - 60mm :VW415A .

-- Press on the 4th gear synchronizer ring -1-, needle bearing for 4th gear assembly -2-, 4th gear assembly -3- and 4th gear thrust washer -4-.

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Conditions

The anti-twist mechanisms -arrow- of the synchronizer ring -1- must be flush with the cut-outs of the locking collar.

Circlip for the 4th gear assembly, determining

The illustration below shows a different component. Determining the circlip is identical.

-- Select and install the thickest circlip that will fit.

Fig 6: Determining Thickness Of Circlip

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Sensor wheel, pressing on

-- Press on the sensor wheel -1- all the way.

Fig 7: Press on the Sensor Ring -1-

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Conditions

Pay attention to the installation position: the high collar -arrow- of the sensor wheel points to the extracting tool 12 of the Extracting Tool - Press In Piece :T40413 .

2 - Extracting Tool 12 of the Extracting Tool : T40413
3 - Press Plate :VW402