AUDI A6 1997 C5 / 2.G 01E Transmission Drive Pinion And Hollow Shaft Assembly Workshop Manual

35-13


Drive pinion and hollow shaft,
disassembling and
assembling

Special tools, testers and auxiliary items
required:

Multi-purpose tool 771/1 with attachment
771/15
Installing sleeve 2003/3
Punch 3013
Thrust pad 3062
Thrust piece 3118
Drift 3138
Drift VW 295
Thrust plate VW 401
Thrust plate VW 402
Pa
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pinion and hollow shaft, disassemblin
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Press tool VW 407
Press tool VW 411
Pa
ge 2 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-14

Press tool VW 412
Tube VW 415a
Support rails VW 457
Separating device 22-115 mm (e.g. Kukko
17/2)
Internal puller 12-14.5 mm (e.g. Kukko 22/1)
Hot air blower V.A.G 1416
Pa
ge 3 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-15


Note:

When installing new gears or final drive set
Page 00
-3 , Technical data
Adjustments are required when replacing
components marked 1) Page 39
-37
,
Adjustment overview
1 -
Gearbox housing
Servicing Page 34
-127
2 -
Shim "S3"
Adjustment overview Page 39
-37Pa
ge 4 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM03.35.2

35-16


3 -
Outer race for large tapered roller bearing
1) Pulling out Fig. 1Pressing in Fig. 2
and Fig. 3
4 -
Drive pinion
1)
Paired with ring gear (final drive set)
5 -
Needle bearing for flange shaft/drive
pinion Pulling out Fig. 4Driving in Fig. 5
6 -
Inner race for large tapered roller bearing
1) Pressing off Fig. 6Pressing on Fig. 7Low-friction bearing; do not oil when
measuring friction torque
Pa
ge 5 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
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pair&id=AUDI.B5.TM03.35.2

35-17


7 -
Circlip
Re-determining Fig. 8
8 -
Flange ring
Installation position Page 34
-68
9 -
Tapered rollers
Qty. 23Installation position Page 34
-68
10 -
Support ring
Installation position Page 34
-68
11 -
Corrugated spring
12 -
Needle bearing for drive pinion/hollow
shaft
Oil before installing
13 -
Hollow shaft with 3rd and 4th speed gears
1)
Pa
ge 6 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
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35-18


14 -
Needle bearing for 2nd speed sliding gear
SplitOil with gear oil before installing
15 -
2nd speed sliding gear Pressing off Fig. 12Before installing, fit spring and slide needle
bearing onto hollow shaft After installing, check axial clearance with
a feeler gauge (0.15-0.35 mm)
16 -
Synchro-ring for 2nd gear Coated with MolybdenumChecking for wear Fig. 2
, Page 35
-9
Pa
ge 7 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
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pair&id=AUDI.B5.TM03.35.2

35-19


17 -
Synchro-hub for 1st and 2nd gear
Pressing off Fig. 12Pressing on Fig. 13Installation position: flush hub towards 2nd
speed sliding gear
18 -
Circlip Removing and installing Fig. 11Re-determining Fig. 8
19 -
Washer
Removing and installing Fig. 11
20 -
Locking collar for 1st and 2nd gear
Installation position: splines for reverse
gear towards synchro-ring for 2nd gear
21 -
Synchro-ring for 1st gear Checking for wear Fig. 2 , Page 35
-9
Pa
ge 8 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
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pair&id=AUDI.B5.TM03.35.2

35-20


22 -
Needle bearing for 1st speed sliding gear
Oil with gear oil before installing
23 -
1st speed sliding gear Before installing, insert spring Fig. 1 ,
Page 35
-9
After pressing on -item 24 -, check axial
clearance
24 -
Inner race for small tapered roller bearing
1) Pressing off Fig. 9Pressing on Fig. 10Low friction bearing; do not oil when
measuring friction torque
25 -
Outer race for small tapered roller bearing
1) Driving out Fig. 15Pressing in Fig. 16
26 -
Shim "S4"
Adjustment overview Page 39
-37Pa
ge 9 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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35-21


27 -
Bearing plate
1)
Servicing Page 34
-112
28 -
6th gear wheel
Pressing off Page 34
-68
Pressing on Page 34
-69
Installation position: shoulder towards inner
race for small tapered roller bearing
29 -
Spacer sleeve
30 -
Shim Re-determining Page 34
-78
31 -
5th gear wheel
Pulling off Page 34
-62
Driving on Page 34
-79
32 -
Circlip for 5th gear wheel
Re-determining Page 34
-80
33 -
End cover
Servicing Page 34
-103
Pa
ge 10 of 21 Drive
pinion and hollow shaft, disassemblin
g and assemblin
g
11/19/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM03.35.2