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Home >> Audi >> 2001 >> A4 Sedan (8D2) V6-2.8L (ATQ) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul (Subassemblies) >> Pinion Shaft, Disassembling & Assembling >> Overview

Pinion Shaft, Disassembling & Assembling: Overview



Special tools and equipment

- 204B installation tool for crankshaft seal
- VVV401 thrust plate
- VW402 thrust plate
- VW407 punch
- VW408A punch
- VW412 punch
- VW415Atube
- VW421 tube
- VW455 thrust tube
- VW519 sleeve
- VW771 slide hammer-complete set
- 2010 sleeve
- 3062 thrust pad
- 3118 sleeve
- 3128 bushing puller
- Kukko 17/2 separating tool
- Kukko 21/1 extractor

Notes:

- When installing the input shaft or the final drive set, consult technical data, Application and ID
- Adjustments are required when replacing components marked with (1), List of Adjustments






1. Transmission - housing
2. Shim S3
- List of adjustments List of Adjustments
3. Double tapered roller bearing outer race
- Pulling out, Fig. 1 Pulling Out Double Tapered Roller Bearing Outer Race.
- Pressing in, Fig. 3 Pressing In Double Tapered Roller Bearing Outer Race.
4. Pinion shaft
- Matched to ring gear; always replace together as a set
- Adjusting pinion shaft and ring gear
- Pinion Shaft, Adjusting
- Ring Gear, Adjusting
5. Tapered roller bearing inner race
- Always replace
- Damaged when removed
- Pressing off, Fig. 2 Pressing Off Double Tapered Roller Bearing Inner Race.
- Pressing on, Fig. 4 Pressing on Double Tapered Roller Bearing Inner Race.
6. Circlip
- Installed position, Fig. 15 Installation Position of Circlips. item 1.
- Redetermine thickness if double roller bearing is replaced, Fig. 5 Determining Thickness of Circlip.
7. Needle bearing for 1st gear
8. 1st gear
9. Spring
- Inserting in 1st gear, Fig. 16 Inserting Spring Into Gear.
- Allocation of spring to gear, Refer to parts supplier.
10. Synchronizer - ring for 1st gear
- Checking for wear, Fig. 17 Checking Synchronizer Ring For Wear.
11. Synchronizer - hub for 1st and 2nd gears
- Pressing off, Fig. 14 Pressing Off Synchronizer Hub For 1ST and 2ND Gears.
- Pressing on, Fig. 18 Pressing on Synchronizer Hub For 1ST and 2ND Gears.
12. Circlip
- Installed position, Fig. 15 Installation Position of Circlips. item -2.
- Redetermine thickness when replacing synchronizer body, Fig. 5 Determining Thickness of Circlip.
13. Needle bearing 2nd gear
14. Operating sleeve for 1st and 2nd gear
- Installed position, Fig. 19 Install Position of Operating Sleeve For 1ST and 2ND.
15. Synchronizer - ring for 2nd gear
- Checking for wear, Fig. 17 Checking Synchronizer Ring For Wear.
16. Spring
- Inserting in 2nd gear, Fig. 16 Inserting Spring Into Gear.
- Allocation of spring to gear, Refer to parts supplier.
17. 2nd gear
18. Circlip
- Installed position, Fig. 15 Installation Position of Circlips, item 3.
19. 3rd gear
- Pressing off, Fig. 13 Pressing Off 3RD Gear.
- Pressing on, Fig. 20 Pressing on 3RD Gear.
20. Circlip
- Identification
- Installed position, Fig. 15 Installation Position of Circlips, item 4.
- If 3rd gear is replaced, redetermine thickness of circlip, Fig. 5 Determining Thickness of Circlip.
21. 4th gear
- Pressing off, Fig. 12 Pressing Off 4TH Gear.
- Pressing on, Fig. 21 Pressing on 4TH Gear.
22. Circlip
- Identification
- Installed position, Fig. 15 Installation Position of Circlips, item 5.
- If 4th gear is replaced, redetermine thickness of circlip, Fig. 5 Determining Thickness of Circlip.
23. Needle bearing
24. 5th gear
25. Spring
- Inserting in 5th gear, Fig. 16 Inserting Spring Into Gear.
- Allocation of spring to gear, Refer to parts supplier.
26. Synchronizer - ring for 5th gear
- Checking for wear, Fig. 17 Checking Synchronizer Ring For Wear.
27. Circlip
- Installed position, Fig. 15 Installation Position of Circlips item 6.
28. Synchronizer - hub for 5th and reverse gear
- Pressing off, Fig. 11 Pressing Off Synchronizer Hub For 5TH and Reverse Gear.
- Pressing on, Fig. 22 Pressing on Synchronizer Hub For 5TH and Reverse Gear.
29. Circlip
- Identification
- Installed position, Fig. 15 Installation Position of Circlips.
- Redetermine thickness when replacing synchronizer hub, Fig. 5 Determining Thickness of Circlip.
30. Needle bearing
- For reverse gear
31. Operating sleeve for 5th and reverse gear
- Installed position, Fig. 23 Install Position of Operating Sleeve For 5TH & Reverse.
32. Synchronizer - ring for reverse gear
- Checking for wear, Fig. 17 Checking Synchronizer Ring For Wear.
33. Spring
- Inserting In reverse gear, Fig. 16 Inserting Spring Into Gear.
- Allocation of spring to gear, Refer to parts supplier.
34. Reverse gear
35. Tapered roller bearing inner race
- Pressing off, Fig. 9 Pressing Off Tapered Roller Bearing Inner Race.
- Pressing on, Fig. 10 Pressing on Tapered Roller Bearing Inner Race.
36. Bushing
- Secures tapered roller bearing inner race
- Pulling out, Fig. 6 Pulling Out Bushing Securing Bearing Outer Race.
- Does not need to be installed after tapered roller bearing has been replaced
37. Tapered roller bearing outer race
- Pulling out, Fig. 7 Pulling Out Tapered Roller Bearing Outer Race.
- Pressing in, Fig. 8 Pressing In Tapered Roller Bearing Outer Race.
38. Shim S4
- List of adjustments List of Adjustments
39. Pressure plate
- Varying thickness, Fig. 25 Pressure Plate Variations
40. Rubber washer
- Compensated length variations
- To remove, install self tapping screw into center of rubber washer and pull out at screw
- Thickness: 7.0 mm (0.28 inch)
41. Transmission - cover
- With reverse idler gear, Service and Repair
- Coat sealing surfaces with thin layer of sealant AMV 188 001 02

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