AUDI A6 2000 C5 / 2.G 01E Transmission Drive Pinion And Hollow Shaft Assembly User Guide

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Fig. 1 Pulling out outer race for large tapered roller bearing
Stepped side of thrust pad 3062 rests against the outer race

Fig. 2 Heating gearbox housing to insert the outer race for large
tapered roller bearing
- Heat gearbox housing in area of bearing seat for approx. 15 minutes,
to approx. 100 C, with a hot air blower.
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Fig. 3 Inserting outer race for large tapered roller bearing in
gearbox housing and pressing home
- Insert outer race only after heating gearbox housing and press home
for 1-2 minutes under a repair press until a heat exchange has taken
place.

Fig. 4 Pulling out needle bearing for flange shaft/drive pinion
A - Internal puller 12-14.5 mm, e.g. Kukko 21/1
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Fig. 5 Driving needle bearing for flange shaft/ drive pinion in
flush

Fig. 6 Pressing off inner race for large tapered roller bearing
A - Separating device 22-115 mm, e.g. Kukko 17/2
Bearing is destroyed when pressing off
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pinion and hollow shaft, disassemblin
g and assemblin
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Fig. 7 Pressing on inner race for large tapered roller bearing
-
Heat inner race to approx. 100 C and fit.- Press home ensuring there is no axial play.
Pa
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pinion and hollow shaft, disassemblin
g and assemblin
g
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Parts catalog
The following circlips are available: Fig. 8 Determining circlip for large tapered roller bearing for
drive pinion
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.Circlip thickness (mm)
2.34 2.40 2.46
2.36 2.42 2.48
2.38 2.44 - Fit circlip.
Pa
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pinion and hollow shaft, disassemblin
g and assemblin
g
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Note:
Do not press off together with 1st and 2nd gear synchro-hub and 2nd
speed sliding gear. Fig. 9 Pressing off inner race of small tapered roller bearing for
drive pinion together with 1st speed sliding gear
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pinion and hollow shaft, disassemblin
g and assemblin
g
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Note: Fig. 10 Pressing on inner race for small tapered roller bearing for
drive pinion together with 1st speed sliding gear
- Install circlip, shim for 1st speed sliding gear, synchro-ring for 1st
speed, and 1st speed sliding gear with spring and needle bearing.
-
Heat inner race to approx. 100 C and fit.- Press home ensuring there is no axial play.
With shoulder of thrust piece 3118 facing downwards, press only onto
bearing inner race. Position stepped shoulder of tube VW 415 A facing up towards press
tool VW 412. After pressing on, check axial clearance of 1st speed sliding gear.
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pinion and hollow shaft, disassemblin
g and assemblin
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Fig. 11 Removing and installing circlip for synchro-hub and shim
for 1st speed sliding gear
- Removing: take off shim -A- then circlip -B-.
- Installing: fit circlip -B- then shim -A-.

Note:
Do not press off together with 1st speed sliding gear and inner race for
small tapered roller bearing. Fig. 12 Pressing off 2nd speed sliding gear with synchro-hub for
1st and 2nd gear
- Take off locking collar for 1st and 2nd gear and synchro-ring for 1st
gear.
- Remove shim and circlip for synchro-hub.
- Press off 2nd speed sliding gear together with synchro-hub for 1st and
2nd gear.
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pinion and hollow shaft, disassemblin
g and assemblin
g
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Note: Fig. 13 Fitting 2nd speed sliding gear, pressing on synchro-hub
for 1st and 2nd gear
- Install needle bearing (split), sliding gear with spring and synchro-ring
for 2nd gear.
- Oil needle bearing.
-
Heat synchro-hub to approx. 100 C and fit.- Press home ensuring there is no axial play.
Position tube VW 415 a with shoulder towards synchro-hub.Position thrust pad 3118 with stepped shoulder towards press tool VW
412.
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pinion and hollow shaft, disassemblin
g and assemblin
g
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yp
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35-31


Parts catalog
The following circlips are available: Fig. 14 Determining thickness of circlip for synchro-hub for 1st
and 2nd gear
- 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 - Fit circlip in direction of arrow onto synchro-hub.
Pa
ge 20 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