1995 AUDI S4 01E Transmission Input Shaft Assembly Workshop Manual

35-9


Fig. 1 Inserting spring in sliding gear
- Insert spring (arrow) in sliding gear, hook angled end into hole.

Fig. 2 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler
gauge at positions -A-, -B- and -C-.
- Add together results and divide by three.

The figure calculated must not be less than 0.5 mm
Pa
ge 9 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.35.1

35-10


Note:
Note installation position when pressing on Fig. 5
.
Note:
The opening of the circlip must align with the groove in the synchro-hub.
Parts catalog
Circlips available Fig. 3 Re-determining thickness of circlip
- Press synchro-hub onto stop.
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05 - Fit circlip.
Pa
ge 10 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.35.1

35-11


Fig. 4 Pressing off synchro-hub for 3rd and 4th gear

Fig. 5 Synchro-hub installation position
Oil groove in synchro hub (arrow -1-) must align with oil drilling -arrow
2- in input shaft
Pa
ge 11 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.35.1

35-12


Fig. 6 Pressing on synchro-hub for 3rd and 4th gear
-
Heat synchro-hub to approx. 100 C, fit and press home.- Fit circlip.

Fig. 7 Driving spring pin into input shaft
- Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B-
in until it touches drift.
Pa
ge 12 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.35.1