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

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41 -
Tapered roller bearing outer race1)
Pressing out Fig. 7Pressing in Fig. 8
42 -
Shim S4
List of adjustments Page 39
-37
43 -
Ring
Holds rubber washerApplication Parts catalog
44 -
Rubber washer
Compensates length variationsApplication Parts catalog
45 -
Transmission cover
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When the bolt is tightened, the outer race will be pulled out of the
housing. Fig. 1 Pulling out double tapered roller bearing outer race
- Remove differential Page 39
-16
.
- Place pressure piece of 3128 bushing puller below outer race.
- Install threaded part of 3128 bushing puller using VW401 thrust plate
onto transmission housing.

Note:
When pressing off, the inner ring of the double tapered roller bearing is
damaged. Fig. 2 Pressing off double tapered roller bearing inner race
- Remove circlip before pressing off.
- Outer race -A- must be installed to press off inner race.
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The smaller diameter of 3062 thrust pad faces outer race. Fig. 3 Pressing in double tapered roller bearing outer race

Fig. 4 Pressing on double tapered roller bearing inner race
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Fig. 5 Determining thickness of circlip
- Determine thickest circlip which can still just be installed and install it.
- Circlips for synchronizer hubs, needle bearings and individual gears
should be determined as for double tapered roller bearing shown.
Available circlips and part numbers Parts catalog

Fig. 6 Pulling out securing bushing for small tapered roller
bearing outer race
A - Puller 12-14.5 mm (0.472-0.570 in.), e.g. Kukko 21/1 puller
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The outer race is pressed out together with pressure plate (item - 43 -),
Page 35
-29
, shim S4 (item -42-) Page 35
-29
and the rubber washer
for compensating length variations (item 44 ), Page 35
-29
. Fig. 7 Pressing out tapered roller bearing outer race

Fig. 8 Pressing in tapered roller bearing outer race
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Fig. 9 Pressing off tapered roller bearing inner race
- Press off inner race together with reverse gear.
A - Separating tool 22-115 mm (0.866-0.590 in.), e.g. Kukko 17/2
separating tool

Fig. 10 Pressing on tapered roller bearing inner race
- Install circlip before pressing on inner race.
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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.
Pa
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pinion and hollow shaft, disassemblin
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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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pinion and hollow shaft, disassemblin
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