2. Remove the bearing race and 1st gear, remove the needle bearing and bushing (photo).
3. Remove the 1st gear synchronizer ring.
4. With the extractor under the 2nd gear, remove it and the 1st/2nd gear synchronizer assembly. Remove the 2nd gear synchronizer ring.
5. Raise the 2nd gear needle bearing, marking its location.
6. The 3rd and 4th gears are firmly seated on the shaft and if they need to be removed, have this work done by an Audi dealer.
7. Assembly is carried out as follows.
8. Lubricate the needles. subsh. 2nd gear, install it on the shaft.
9. Install the 2nd gear on the bearing, place the synchronizer ring on the gear. Measure the gap as shown in Fig. 6.5 if the gap exceeds the value given in Specifications, the synchronizer ring must be replaced with a new (photo).
10. If the synchronizer has been disassembled, assemble it in the following way. The bushing and hub may have alignment marks. Install the three locking keys in their grooves, secure the retaining rings. The retaining rings must be 120°apart, the end of the retaining ring must be inserted into the hole of the blocking cotter. If there are no alignment marks on the hub and bushing, assemble them in any position, the grooves on the grooves of the hub must face the 1st gear.
11. Install the synchronizer assembly on the shaft, with the end of the sleeve with external teeth towards the gear. Before pushing the hub all the way down, rotate the 2nd gear synchro ring so that the grooves in it line up with the locking cotters in the synchro assembly (photo).
12. Install the 1st gear synchronizer ring, aligning the slots with the locking cotters in the synchronizer assembly. Late models have a modified synchronizer ring with a missing tooth in three places (Pic. 6.8). The tooth angle on these synchronizer rings has been changed from 120°to 110°to improve 1st gear engagement. This type of ring should only be used on the 1st gear, and if the 1st gear ring is being replaced, install a full 120°type ring as the modified ring is not available as a rebuild ring.
13. Install the 1st gear support sleeve, lubricate the needles. subsh. and install it on the bushing (photo).
14. Install the 1st gear, then press the 2nd taper bearing inner race (photo).
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