1999 AUDI A4 01A Transmission Drive Pinion And Hollow Shaft Assembly Workshop Manual

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Fig. 11 Pressing off synchronizer hub for 5th gear and reverse
idler gear
- Remove circlip before pressing off.
- Press off synchronizer hub together with 5th gear.
A - Separating tool 22-115 mm (0.866-0.590 in.), e.g. Kukko 17/2
separating tool

Fig. 12 Pressing off 4th gear
- Remove circlip before pressing off.
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Fig. 13 Pressing off 3rd gear
- Remove circlip before pressing off.
- Press off 3rd gear together with 2nd gear.
A - Separating tool 22-115 mm (0.866-0.590 in.), e.g. Kukko 17/2
separating tool

Fig. 14 Pressing off 1st and 2nd gear synchronizer hub
- Remove circlip before pressing off.
- Press off synchronizer hub together with 1st gear.
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Fig. 15 Allocation of circlips
- Circlips for synchronizer hubs, needle bearings and individual gears
should be determined according to Fig. 5
.
Circlip
- 1- secures the 1st and 2nd gear synchronizer hub
Identification: color blueCirclip thickness (mm)
1.90 1.96 2.02
1.93 1.99 Circlip
- 2- secures the needle bearing/ 2nd gear
Thickness: 2.00 mm (0.078 in.). Identification: color blue
Circlip
- 3- secures the 3rd gearCirclip thickness (mm)
1.90 1.98 2.06
1.94 2.02
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Circlip -4- secures the 4th gear.

Circlip thickness (mm)
1.86 1.94
1.90 1.98

Circlip -5- secures the needle bearing/ 5th gear
Thickness 2.00 mm (0.078 in.)
Identification: color brown
Circlip -6- secures the synchronizer hub for 5th and reverse gear
Identification: color blueCirclip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05 Circlip -7- secures needle bearing for reverse gear
Thickness 2.50 mm (0.098 in.)
- Determine circlips according to table. Part number parts catalog
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The bent end of the spring (arrow) must be hooked into the hole in the
gear. Fig. 16 Inserting spring in gear

The average gap must not be less than 0.5 mm (0.019 in.). Fig. 17 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 calculated measurements and divide by 3.
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Allocation: higher inner collar faces 2nd gear. Fig. 18 Pressing on 1st and 2nd gear synchronizer hub

Fig. 19 Allocation of 1st and 2nd gear operating sleeve
Chamfer (arrow -1-) faces 2nd gear.Stepped side (arrow -2-) faces 1st gear.
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Allocation: the groove on the gear faces 4th gear. Fig. 20 Pressing on 3rd gear

Allocation: higher inner collar faces 3rd gear. Fig. 21 Pressing on 4th gear
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Allocation: higher inner collar faces 5th gear. Fig. 22 Pressing on 5th and reverse gear synchronizer hub

Operating sleeves with chamfer -A- as well as operating sleeves with
large offset -B- are installed.
Note the location of operating sleeve to reverse idler gear Fig. 24
.
Allocation: Fig. 23 Allocation of operating sleeve for 5th and reverse gears
Chamfer (arrow -1-) faces reverse idler gearSmaller offset (arrow -2-) faces 5th gearLarger offset (arrow -3-) faces reverse idler gear
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