2000 AUDI A4 01W Transmission Pinion Shaft Workshop Manual

35-34


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

Fig. 12 Pressing off 4th gear
- Remove circlip before pressing off.
Pa
ge 17 of 26 Pinion 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.TM01.35.3

35-35


Fig. 13 Pressing off 3rd gear
- Remove circlip before pressing off.
- Press off 3rd gear together with 2nd gear.
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool

Fig. 14 Pressing off synchronizer hub for 1st and 2nd gears
- Remove circlip before pressing off.
- Press off synchronizer hub together with 1st gear.
Pa
ge 18 of 26 Pinion 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.TM01.35.3

35-36


Fig. 15 Installation position of circlips
- Circlips for synchronizer hubs, needle bearings and individual gears
should be determined as shown in Fig. 5
.
Circlip -1- secures the tapered roller bearing inner race.
Circlip thickness (mm)
2.00 2.06 2.12
2.03 2.09 2.15
Circlip -2- secures the synchronizer hub for 1st and 2nd gear.
Characteristic: blue in color
Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99
Circlip -3- secures the needle bearing for 2nd gear.
Characteristic: blue in color
Thickness: 2.50 mm (0.098 in.)
Pa
ge 19 of 26 Pinion 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.TM01.35.3

35-37


Circlip -4- secures the 3rd gear
Circlip thickness (mm)
1.90 1.98 2.06
1.94 2.02
Circlip -5- secures the 4th gear
Circlip thickness (mm)
1.86 1.94
1.90 1.98
Circlip -6- secures the needle bearing for 5th gear.
Thickness: 2.00 mm (.0787 in.)
Identification: brown in color
Pa
ge 20 of 26 Pinion 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.TM01.35.3

35-38


Circlip -7- secures the synchronizer hub for 5th and reverse gear.
Characteristic: blue in color
Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05 - Determine circlips according to table. Part numbers parts catalog

The bent end of the spring (arrow) must be hooked into the hole of the
gear. Fig. 16 Inserting spring into gear
Pa
ge 21 of 26 Pinion 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.TM01.35.3

35-39


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 measured values and divide total by three to calculate average.
The calculated gap must not be less than 0.5 mm (0.002 in.).

Fig. 18 Pressing on synchronizer hub for 1st and 2nd gears
Installation position:
Higher inner collar faces 2nd gear.
Pa
ge 22 of 26 Pinion 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.TM01.35.3

35-40


Installation position: Fig. 19 Installation position of operating sleeve for 1st and 2nd
gear

Chamfer (arrow -1-) faces 2nd gear
Stepped side (arrow -2-) faces 1st gear

Installation position: the groove on the gear faces 4th gear. Fig. 20 Pressing on 3rd gear
Pa
ge 23 of 26 Pinion 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.TM01.35.3

35-41


Installation position: higher inner collar faces 3rd gear. Fig. 21 Pressing on 4th gear

Installation position: higher inner collar faces 5th gear.
Note:
The large inner diameter of 2010 sleeve faces the synchronizer hub. Fig. 22 Pressing on synchronizer hub for 5th and reverse gear
Pa
ge 24 of 26 Pinion 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.TM01.35.3