AUDI A6 1996 C5 / 2.G 01E Transmission Input Shaft Assembly Workshop Manual

35-1


Input shaft, disassembling
and assembling

Special tools, testers and auxiliary items
required:

Thrust plate VW 401
Press tool VW 412
Tube VW 519
Feeler gauge
Pa
ge 1 of 12 In
put shaft, disassemblin
g and assemblin
g
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yp
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35-2


Note:
When installing new gears Page 00
-3 , Technical
data
1 -
Gearbox housing
Servicing Page 34
-127
2 -
Circlip
3 -
Thrust washer
4 -
Needle bearing for 4th gear
Mark before removingDo not interchange with needle bearing for
3rd gear Oil with gear oil before installing
5 -
4th speed sliding gear Before installing, insert spring Fig. 1After installing, check axial clearance with a
feeler gauge (0.15-0.35 mm)
Pa
ge 2 of 12 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.TM03.35.1

35-3


6 -
Synchro-ring for 4th gear
Check for wear Fig. 2
7 -
Locking collar
Paired with synchro-hubMark before removing Page 34
-63
8 -
Circlip
Re-determine thickness when replacing
synchro-hub Fig. 3

Installation position: ends align with groove
of synchro-hub
9 -
Synchro-hub for 3rd and 4th gear Pressing off Fig. 4Installation position Fig. 5Pressing on Fig. 6
Pa
ge 3 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
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pair&id=AUDI.B5.TM03.35.1

35-4


10 -
Synchro-ring for 3rd gear
Coated with molybdenumCheck for wear Fig. 2
11 -
3rd speed sliding gear
Before installing, insert spring Fig. 1After pressing on -item 9 -, check axial
clearance with a feeler gauge (0.15-0.35
mm)
12 -
Needle bearing for 3rd gear Mark before removingDo not interchange with needle bearing for
4th gear Oil with gear oil before installing
13 -
Input shaft
Pa
ge 4 of 12 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.TM03.35.1

35-5


14 -
Spring pin
Drive in when replacing input shaft Fig. 7
15 -
Bearing plate
Servicing Page 34
-112
16 -
Inner race for cylinder roller bearing
Take off and fit by hand
17 -
Circlip
18 -
Thrust washer for needle bearing for 6th
gear Installation position: shoulder towards
circlip, smooth contact surface towards
needle bearing Page 34
-75

Pa
ge 5 of 12 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.TM03.35.1

35-6


19 -
Needle bearing for 6th gear
Oil with gear oil before installing
20 -
6th speed sliding gear Before installing, insert spring Fig. 1After installing, check axial clearance with
a feeler gauge (0.15-0.35 mm)
21 -
Synchro-ring for 6th gear Check for wear Fig. 2
22 -
Synchro-hub for 5th and 6th gear
Pulling off Page 34
-64
Driving on Page 34
-76
Installation position: projecting hub towards
5th speed sliding gear
Pa
ge 6 of 12 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.TM03.35.1

35-7


23 -
Locking collar
Paired with synchro-hubMark before removing Page 34
-63
24 -
Synchro-ring for 5th gear
Checking for wear Fig. 2
25 -
5th speed sliding gear
Before installing, insert spring Fig. 1After installing, check axial clearance
Page 34
-81

26 -
Inner race for 5th speed sliding gear
Pulling off Page 34
-64
Driving on Page 34
-81
Pa
ge 7 of 12 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.TM03.35.1

35-8


27 -
Needle bearing for 5th gear
Oil with gear oil before installing
28 -
1st inner race for tapered roller bearing
for input shaft Pulling off Page 34
-61
Driving on Page 34
-81
29 -
End cover
Servicing Page 34
-103
30 -
2nd inner race for tapered roller bearing
for input shaft
Pulling off Page 34
-61
Driving on Page 34
-82
31 -
Multi-point socket head bolt, 150 Nm
Loosening and tightening Page 34
-60
Pa
ge 8 of 12 In
put shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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pair&id=AUDI.B5.TM03.35.1

35-9


Fig. 1 Inserting spring in sliding gear
- Insert spring (arrow) in sliding gear, hook angled end into hole.

Fig. 2 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler
gauge at positions -A-, -B- and -C-.
- Add together results and divide by three.

The figure calculated must not be less than 0.5 mm
Pa
ge 9 of 12 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.TM03.35.1

35-10


Note:
Note installation position when pressing on Fig. 5
.
Note:
The opening of the circlip must align with the groove in the synchro-hub.
Parts catalog
Circlips available Fig. 3 Re-determining thickness of circlip
- Press synchro-hub onto stop.
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05 - Fit circlip.
Pa
ge 10 of 12 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.TM03.35.1