1996 AUDI A4 01W Transmission Input Shaft Workshop Manual

35-6


Fig. 1 Securing bolt for needle bearing
- Remove securing bolt (arrow).

Fig. 2 Driving out needle bearing
Pa
ge 9 of 19 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.TM01.35.1

35-7


Notes:
To avoid damage due to improper assembly, check the following after
replacing the input shaft: Fig. 3 Allocation of input shaft/needle bearingInput shaft diameter
Needle bearing part number
a: 27 mm (1.062 in.) 012 311 123 D
a: 29 mm (1.141 in) 012 311 123
Input shaft must be able to be guided in.Input shaft must have no play.

Dimension -a- from lower edge of straight-edge to upper edge of needle
bearing: 39.5 mm (1.555 in.)
Note:
Measure the dimension from the top edge of the straight-edge and
subtract the height of the straight-edge from the measured dimension. Fig. 4 Allocation of needle bearing
Pa
ge 10 of 19 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.TM01.35.1

35-8


Fig. 5 Pressing in needle bearing
- Install securing bolt and tighten to 25 Nm (18 ft lb).

Tightening torque: 25 Nm (18 ft lb). Fig. 6 Installing securing bolt (arrow)
Pa
ge 11 of 19 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.TM01.35.1

35-9


Installed position: Flared edge of oiling sleeve faces tool
Installation depth: 3.5 mm (0.138 in.) below upper edge Fig. 7 Driving in oiling sleeve into input shaftItem
Diameter of oiling sleeve
Tool
A 14 mm (0.551 in.) VW222A pilot drift
B 16 mm (0.629 in.) 30-24 drift

Fig. 8 Pulling out roller sleeve
A - Internal puller 22-28 mm, e.g. Kukko 21/4
Plastic sleeve inside roller sleeve must be destroyed to install internal
puller.
Pa
ge 12 of 19 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.TM01.35.1

35-10


Dimension -a- = 216 mm (8.5 in.)
Note:
Measure from upper edge of cover to upper edge of bearing. Fig. 9 Installed position of roller sleeve

Fig. 10 Driving in roller sleeve
Pa
ge 13 of 19 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.TM01.35.1

35-11


Fig. 11 Pressing off 5th gear
- Remove circlip before pressing off.
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool

Fig. 12 Pressing off synchronizer hub for 3rd and 4th gears
- Remove circlip before pressing off.
- Press 3rd gear synchronizer ring (arrow) toward 3rd gear, and install
separating device -A-.
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool
Pa
ge 14 of 19 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.TM01.35.1

35-12


The bent end of the spring (arrow) must be hooked into the hole of the
gear. Fig. 13 Inserting spring into gear

Fig. 14 Checking synchronizer ring for wear
- Press synchronizer ring into operating sleeve and measure gap -a-
using feeler gauge at positions -A-, -B- and -C-.
- Add measured values and divide total by three to calculate average.
The calculated gap must not be less than 0.5 mm (0.019 in.).
Pa
ge 15 of 19 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.TM01.35.1

35-13


Fig. 15 Allocation of circlips
Circlips -1- and -2- secure the input shaft ball bearing.
Determining thickness Page 35
-17
, input shaft, adjusting
Circlip -3- secures the 3rd and 4th gear synchronizer hub.
Thickness: 2.00 mm (0.078 in.).
Identification: brown in color.Circlip -4- secures the 3rd and 4th gear synchronizer hub.
Determining thickness Page 35
-14
, table
Identification: blue in color.
Circlip -5- secures the 5th gear.
Determining thickness Page 35
-14
, table
Pa
ge 16 of 19 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.TM01.35.1