AUDI A4 1996 B5 / 1.G 01W Transmission Input Shaft Workshop Manual

35-1


Input shaft, disassembling
and assembling

Special tools and equipment

VW222A pilot drift
VW295 needle-bearing drift
VW295A needle-bearing drift
VW401 thrust plate and VW402 thrust plate
VW407 punch and VW408A punch
VW415A tube and VW416B tube
VW447I thrust pad
VW771 slide hammer-complete set
30-24 drift
30-100 press tube

Pa
ge 1 of 19 In
put 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.TM01.35.1

40-105 thrust piece
40-202 press-out piece
Kukko 17/2 separating tool
21/4 KUKKO extractor
Pa
ge 2 of 19 In
put 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.TM01.35.1

35-2


Notes:

When installing the input shaft or new gears,
consult technical data Page 00
-3 .
By replacing items - 2 -, - 4 - and/or - 6 -, the
position of the ball bearing is influenced. In this
case, the input shaft must be re-adjusted
Page 35
-17
.
1 -
Circlip
IdentificationInstalled position Fig. 15
, item -1-
Determining thickness Page 35
-17
2 -
Input shaft ball bearing
Removing and installing Page 34
-49
3 -
Circlip
IdentificationInstalled position Fig. 15
, item -2-
Determining thickness Page 35
-17
4 -
Transmission housing
Pa
ge 3 of 19 In
put 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.TM01.35.1

35-3


5 -
Needle bearing
Secured with bolt Fig. 1Driving out Fig. 2Allocation of input shaft/needle bearing
Fig. 3

Installed position Fig. 4Pressing in Fig. 5Securing Fig. 6
6 -
Input shaft
With oiling sleeveDriving in oiling sleeve Fig. 7Adjusting Page 35
-17
Allocation of input shaft/needle bearing
Fig. 3

7 -
Needle bearing for for 3rd gear
Identification
8 -
3rd gear
9 -
Spring Inserting in 3rd gear Fig. 13Allocation of spring to gear parts catalog
10 -
Synchronizer ring for 3rd gear
Pa
ge 4 of 19 In
put 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.TM01.35.1

Checking for wear Fig. 14
Pa
ge 5 of 19 In
put 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.TM01.35.1

35-4


11 -
Circlip
IdentificationInstalled position Fig. 15
, item -3-
12 -
Synchronizer hub for 3rd and 4th gears
Shoulder faces third gearPressing off Fig. 12Pressing on Fig. 17
13 -
Circlip
IdentificationInstalled position Fig. 15
, item 4
Re-determining thickness when replacing
synchronizer body Fig. 16

14 -
Operating sleeve for 3rd and 4th gears
Installed position Fig. 18
15 -
Synchronizer ring for 4th gear
Checking for wear Fig. 14
16 -
Spring
Inserting in 4th gear Fig. 13Allocation of spring to gear parts catalog
17 -
4th gear
Pa
ge 6 of 19 In
put 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.TM01.35.1

35-5


18 -
Needle bearing for 4th gear
Identification
19 -
5th gear Pressing off Fig. 11Pressing on Fig. 19
20 -
Circlip
IdentificationInstalled position Fig. 15
, item -5-
If 5th gear is replaced, re-determine
thickness of circlip Fig. 16

21 -
Roller sleeve
Always replaceDamaged when removedPulling out Fig. 8Installed position Fig. 9Driving in Fig. 10
22 -
Plastic sleeve
Made of plastic
23 -
Transmission cover With reverse idler gear Page 35
-44Pa
ge 7 of 19 In
put 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.TM01.35.1

Coat sealing surfaces with a thin layer of
sealant AMV 188 001 02
Pa
ge 8 of 19 In
put 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.TM01.35.1

35-6


Fig. 1 Securing bolt for needle bearing
- Remove securing bolt (arrow).

Fig. 2 Driving out needle bearing
Pa
ge 9 of 19 In
put 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.TM01.35.1

35-7


Notes:
To avoid damage due to improper assembly, check the following after
replacing the input shaft: Fig. 3 Allocation of input shaft/needle bearingInput shaft diameter
Needle bearing part number
a: 27 mm (1.062 in.) 012 311 123 D
a: 29 mm (1.141 in) 012 311 123
Input shaft must be able to be guided in.Input shaft must have no play.

Dimension -a- from lower edge of straight-edge to upper edge of needle
bearing: 39.5 mm (1.555 in.)
Note:
Measure the dimension from the top edge of the straight-edge and
subtract the height of the straight-edge from the measured dimension. Fig. 4 Allocation of needle bearing
Pa
ge 10 of 19 In
put 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.TM01.35.1