1999 AUDI A4 01W Transmission Pinion Shaft Workshop Manual

35-21


Pinion shaft, disassembling
and assembling

Special tools and equipment

204B installation tool for crankshaft seal
VW401 thrust plate
VW402 thrust plate
VW407 punch
VW408A punch
VW412 punch
VW415A tube
VW421 tube
VW455 thrust tube
VW519 sleeve

Pa
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pair&id=AUDI.B5.TM01.35.3

VW771 slide hammer-complete set
Pa
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35-22

2010 sleeve
3062 thrust pad
3118 sleeve
3128 bushing puller
Kukko 17/2 separating tool
Kukko 21/1 extractor
Pa
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11/19/2002 htt
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35-23


Notes:

When installing the input shaft or the final drive
set, consult technical data Page 00
-3 .
Adjustments are required when replacing
components marked with 1): Page 39
-33
, list
of adjustments
1 -
Transmission housing
2 -
Shim S3
List of adjustments Page 39
-33
3 -
Double tapered roller bearing outer race
1)
Pulling out Fig. 1Pressing in Fig. 3
4 -
Pinion shaft 1)
Matched to ring gear; always replace
together as a set Adjusting pinion shaft and ring gear
Page 39
-29

5 -
Tapered roller bearing inner race1)
Always replaceDamaged when removedPressing off Fig. 2Pressing on Fig. 4
Pa
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35-24


6 -
Circlip
IdentificationInstalled position Fig. 15
, item -1-
Re-determine thickness if double roller
bearing is replaced Fig. 5

7 -
Needle bearing for for 1st gear
8 -
1st gear
9 -
Spring
Inserting in 1st gear Fig. 16Allocation of spring to gear parts catalog
10 -
Synchronizer ring for 1st gear
Checking for wear Fig. 17
11 -
Synchronizer hub for 1st and 2nd gears
Pressing off Fig. 14Pressing on Fig. 18
12 -
Circlip
IdentificationInstalled position Fig. , item -2-Re-determine thickness when replacing
synchronizer body Fig. 5

Pa
ge 5 of 26 Pinion shaft, disassemblin
g and assemblin
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11/19/2002 htt
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pair&id=AUDI.B5.TM01.35.3

35-25


13 -
Needle bearing 2nd gear
14 -
Operating sleeve for 1st and 2nd gear
Installed position Fig. 19
15 -
Synchronizer ring for 2nd gear
Checking for wear Fig. 17
16 -
Spring
Inserting in 2nd gear Fig. 16Allocation of spring to gear parts catalog
17 -
2nd gear
18 -
Circlip
IdentificationInstalled position Fig. 15
, item -3-
19 -
3rd gear
Pressing off Fig. 13Pressing on Fig. 20
20 -
Circlip
IdentificationInstalled position Fig. 15
, item -4-
If 3rd gear is replaced, re-determine
thickness of circlip Fig. 5

Pa
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g and assemblin
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11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
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pair&id=AUDI.B5.TM01.35.3

35-26


21 -
4th gear
Pressing off Fig. 12Pressing on Fig. 21
22 -
Circlip
IdentificationInstalled position Fig. 15
, item -5-
If 4th gear is replaced, re-determine
thickness of circlip Fig. 5

23 -
Needle bearing
24 -
5th gear
25 -
Spring
Inserting in 5th gear Fig. 16Allocation of spring to gear parts catalog
26 -
Synchronizer ring for 5th gear
Checking for wear Fig. 17
27 -
Circlip
IdentificationInstalled position Fig. 15
, item -6-
28 -
Synchronizer hub for 5th and reverse gear
Pressing off Fig. 11
Pa
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g and assemblin
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11/19/2002 htt
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pair&id=AUDI.B5.TM01.35.3

Pressing on Fig. 22
Pa
ge 8 of 26 Pinion shaft, disassemblin
g and assemblin
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11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.35.3