AUDI A4 1997 B5 / 1.G 01W Transmission Input Shaft User Guide

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Fig. 5 Pressing in needle bearing
- Install securing bolt and tighten to 25 Nm (18 ft lb).

Tightening torque: 25 Nm (18 ft lb). Fig. 6 Installing securing bolt (arrow)
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Installed position: Flared edge of oiling sleeve faces tool
Installation depth: 3.5 mm (0.138 in.) below upper edge Fig. 7 Driving in oiling sleeve into input shaftItem
Diameter of oiling sleeve
Tool
A 14 mm (0.551 in.) VW222A pilot drift
B 16 mm (0.629 in.) 30-24 drift

Fig. 8 Pulling out roller sleeve
A - Internal puller 22-28 mm, e.g. Kukko 21/4
Plastic sleeve inside roller sleeve must be destroyed to install internal
puller.
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Dimension -a- = 216 mm (8.5 in.)
Note:
Measure from upper edge of cover to upper edge of bearing. Fig. 9 Installed position of roller sleeve

Fig. 10 Driving in roller sleeve
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Fig. 11 Pressing off 5th gear
- Remove circlip before pressing off.
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool

Fig. 12 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, e.g. Kukko 17/2 separating tool
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The bent end of the spring (arrow) must be hooked into the hole of the
gear. Fig. 13 Inserting spring into gear

Fig. 14 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 total by three to calculate average.
The calculated gap must not be less than 0.5 mm (0.019 in.).
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Fig. 15 Allocation of circlips
Circlips -1- and -2- secure the input shaft ball bearing.
Determining thickness Page 35
-17
, input shaft, adjusting
Circlip -3- secures the 3rd and 4th gear synchronizer hub.
Thickness: 2.00 mm (0.078 in.).
Identification: brown in color.Circlip -4- secures the 3rd and 4th gear synchronizer hub.
Determining thickness Page 35
-14
, table
Identification: blue in color.
Circlip -5- secures the 5th gear.
Determining thickness Page 35
-14
, 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. 16 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. 17 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. 18 Installation position 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!
Installation position: shoulder faces reverse gear. Fig. 19 Pressing on 5th gear
-
Heat 5th gear to approx. 100 C (212 F) before pressing on.
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