AUDI A4 1996 B5 / 1.G 01A Transmission Drive Pinion And Hollow Shaft Assembly Workshop Manual

35-21


Drive pinion and hollow shaft,
disassembling and
assembling

Special tools and equipment

VW401 thrust plate
VW402 thrust plate
VW407 punch
VW411 punch
VW412 thrust disc
415A tube
416B tube
418A tube
429 thrust ring
VW4471 thrust pad
Pa
ge 1 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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VW454 thrust tube
VW519 sleeve
VW771 slide hammer-complete set
Pa
ge 2 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-22

40-103 sleeve
2010 sleeve
3062 thrust pad
3128 bushing puller
Kukko 17/2 separating tool
Kukko 21/1 puller
Pa
ge 3 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-23


Notes:

When installing new gears or the final drive set,
consult technical data Page 00
-3 .
Adjustments are required when replacing
components marked by1) Page 39
-37
, List
of adjustments
1 -
Transmission housing
2 -
Shim S3
List of adjustments overview Page 39
-37
3 -
Double tapered roller bearing outer race1)
Replace together with item - 5 -Pulling out Fig. 1Pressing in Fig. 3
4 -
Drive pinion
Matched to ring gear, always replace
together as a set Adjusting drive pinion and ring gear
Page 39
-34

Pa
ge 4 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-24


5 -
Double tapered roller bearing inner race1)
Always replaceDamaged when removedPressing off Fig. 2Pressing on Fig. 4
6 -
Circlip
Re-determine thickness if double roller
bearing is replaced Fig. 5

7 -
Needle bearing for hollow shaft1)
For drive pinion in hollow shaftLubricate with MOS2 grease
8 -
Hollow shaft1)
9 -
Needle bearing for 1st gear
10 -
Needle bearing for 1st gear
11 -
1st gear
12 -
Spring Inserting in 1st gear Fig. 16Application of spring to gear Parts
catalog
Pa
ge 5 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-25


13 -
Synchronizer ring for 1st gear
Checking for wear Fig. 17
14 -
Synchronizer hub for 1st and 2nd gear
Pressing off Fig. 14Pressing on Fig. 18
15 -
Circlip
IdentificationAllocation Fig. 15
, item -1-
Re-determining thickness if synchronizer
hub is replaced Fig. 5

16 -
Needle bearing for 2nd gear
17 -
Operating sleeve for 1st and 2nd gear
Allocation Fig. 19
18 -
Synchronizer ring for 2nd gear
Checking for wear Fig. 17
19 -
Spring
Inserting in 2nd gear Fig. 16Application of spring to gear Parts
catalog
20 -
2nd gear
Pa
ge 6 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-26


21 -
Circlip
IdentificationAllocation Fig. 15
item -2-
22 -
3rd gear
Pressing off Fig. 13Pressing on Fig. 20
23 -
Circlip
IdentificationAllocation Fig. 15
, item -3-
Re-determining thickness if 3rd gear is
replaced Fig. 5

24 -
4th gear
Pressing off Fig. 12Pressing on Fig. 21
25 -
Circlip
IdentificationAllocation Fig. 15
, item -4-
Re-determining thickness if 4th gear is
replaced Fig. 5

26 -
Needle bearing
27 -
5th gear
Pa
ge 7 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-27


28 -
Spring
Inserting in 5th gear Fig. 16Application of spring to gear Parts
catalog
29 -
Synchronizer ring for 5th gear
Checking for wear Fig. 17
30 -
Circlip
IdentificationAllocation Fig. 15
, item -5-
31 -
Synchronizer hub for 5th gear and reverse
gear
Pressing off Fig. 11Pressing on Fig. 22
32 -
Circlip
IdentificationAllocation Fig. 15
, item -6-
Re-determining thickness if synchronizer
hub is replaced Fig. 5

33 -
Needle bearing
For reverse gear
34 -
5th and reverse gear operating sleeve
Pa
ge 8 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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Allocation Fig. 23
Pa
ge 9 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-28


35 -
Synchronizer ring for reverse gear
Checking for wear Fig. 17
36 -
Spring
Insert in reverse gear Fig. 16Application of spring to gear Parts
catalog
37 -
Reverse gear
38 -
Circlip
IdentificationAllocation Fig. 15
, item -7-
39 -
Tapered roller bearing inner race1)
Pressing off Fig. 9Pressing on Fig. 10
40 -
Bushing
To secure small tapered roller bearing
outer race Pulling out Fig. 6Does not need to be installed after small
tapered roller bearing has been replaced
Pa
ge 10 of 25 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/20/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM02.35.3