AUDI A4 1996 B5 / 1.G 01A Transmission Assembly Owner's Manual

34-61

Installing

Note:
If the input shaft ball bearing, the input shaft or
the transmission housing are replaced, it is
necessary to re-determine the thickness of the
circlips for the input shaft first, input shaft,
adjusting Page 35
-17
.

- For easier installation of following components, swing transmission
housing into position shown.

Note:
The relay shaft -C- and the shift rod can also be installed later if
necessary Page 34
-62
, Illustration V34-1816 and Page 34
-63
,
illustration V34-2120 - Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods
-D- with shift rod and selector forks -E-.
- Install these components into transmission housing as a set.
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34-62


Position of shift mechanism in transmission.
Note:
Illustration is shown without the drive axle and pinion. 1 - Shift fork 5th and reverse gears
2 - Shift fork 3rd and 4th gears
3 - Shift fork 1st and 2nd gears
4 - Relay shaft
5 - Shift detent
6 - Shift rod

- Move transmission housing and engage 3rd gear (direction of arrow).
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34-63


- Install relay shaft -A-.
- Place inner shift rod -B- sideways into mounting hole in transmission
housing and assemble into mounting eye.
- Carefully turn shift rod in direction of arrow.

- Insert shift detent and tighten bolt (arrow) securely.
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34-64


- Install relay shaft stop bolts (arrows).
- Replace O-ring for multi-function switch.

- Carefully insert multi-function switch and tighten (arrows).
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34-65


- Make sure dowel sleeves for transmission cover -A- are installed in
transmission housing -B- (arrows).
- Install transmission cover onto transmission housing.

- Make sure dowel sleeves for cover -A- are installed in transmission
cover -B- (arrows).
- Install compression spring -C-.
- Install Torsen differential cover -A- onto transmission cover -B-.
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34-66


- Install rear circlip (arrow) for ball bearing onto input shaft.
- Slide ball bearing onto input shaft.
Closed side of ball cage faces toward transmission housing.

- Press in ball bearing.
- Slide thrust piece -A- of press device onto input shaft.
- Position press device behind splines for clutch plate.
- Screw in bolts -B- and tighten slightly.
The bolts bear against the indentations in thrust piece -A-.
- Press in ball bearing onto seat by alternately tightening bolts -B- (1/2-
turn at a time) until stop is reached.
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34-67


Notes: - Install front circlip -D- for input shaft ball bearing.
- Install dished washer -C-.
Position: convex side faces guide sleeve -B-.
Before installing guide sleeve, cover splines on input shaft with a
shrink-fit hose to protect the seal. Installing seal in guide sleeve Page 30
-20
.
- Install guide sleeve -B- for clutch release bearing.
- Install clutch release lever -A- and clutch release bearing.
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