AUDI A4 1996 B5 / 1.G 01A Transmission Input Shaft Assembly User Guide

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Fig. 9 Driving in roller sleeve

Fig. 10 Pressing off 5th gear
- Remove circlip before pressing off.
A- Separating device 22-115 mm (0.866-4.527 in.), e.g. Kukko 17/2
separating tool
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Fig. 11 Pressing off synchronizer hub for 3rd and 4th gears
- Remove circlip before pressing off.
- Press 3rd gear synchronizer ring (arrow) toward 3rd gear and install
separating device -A-.
A- Separating device 22-115 mm (0.866-4.527 in.), e.g. Kukko 17/2
separating tool

The bent end of the spring (arrow) must be hooked into the hole of the
gear. Fig. 12 Inserting spring in gear
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The calculated gap must not be less than 0.5 mm (0.019 in.). Fig. 13 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 by 3 to calculate average.
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Fig. 14 Allocation of circlips
The circlips -1- and -2- secure the input shaft ball bearing.
Determining thickness Page 35
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, input shaft, adjusting
The circlip -3- secures the 3rd and 4th gear synchronizer hub.
Thickness: 2.00 mm (0.078 in.)
Identification: brown color
The circlip -4- secures the 3rd and 4th gear synchronizer hub.
Determining thickness Page 35
-14
, table
Identification: blue color
The circlip -5- secures the 5th gear.
Determining thickness Page 35
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, table
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The following circlips are available for synchronizer hub for 3rd and
4th gear
The following circlips are available for 5th gear Fig. 15 Determining thickness of circlip
- Determine thickest circlip which can still just be installed and install it.
- Determine circlip according to table. Part number parts catalogCirclip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05 Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99
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Fig. 16 Pressing on synchronizer hub for 3rd and 4th gears

Operating sleeves with chamfer -A- as well as operating sleeves with a
large offset -B- are installed.
Installed position: Fig. 17 Allocation of operating sleeve
The chamfer (arrow -1-) faces 4th gearThe small stepped side (arrow -2-) faces 3rd gearThe large stepped side (arrow -3-) faces 4th gear
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WARNING!
Wear protective gloves.
Allocation: wider collar faces reverse gear. Fig. 18 Pressing on 5th gear
-
Heat 5th gear to approx. 100 C (212 F) before pressing on.
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