2. Clamp the output shaft in a vice on the visible part between the 3rd and 4th gears.
3. Using an extractor, remove the inner bearing ring from the pinion gear.
4. Remove the 1st gear needle bearing.
5. Remove the 1st gear synchronizer ring and install it on the gear.
6. Remove the retaining ring located opposite the synchronizer hub.
7. Insert the extractor with your feet under the 2nd gear, remove it with the 1/2 gear synchronizer assembly.
8. Lift the needle assembly of the 2nd gear, install it inside the gear.
9. The 3rd and 4th gears are pressed onto the shaft and if they need to be removed or the bearing at the end of the gears needs to be replaced, see your Audi dealer.
10. Begin assembly with the large inner bearing race, 4th gear, snap ring, 3rd gear and snap ring on the shaft as follows.
11. Lubricate the needle bearing of the 2nd gear with transmission oil, install it on the shaft.
12. Install the 2nd gear on the bearing, then place the synchronizer ring on the gear. Measure the gap shown in Fig. 6.5. If the gap exceeds the value given in the Specifications, install a new synchronizer ring.
13. If the synchronizer assembly has been disassembled, it must be assembled in the following way. Install three locking crackers into the grooves in the hub, secure them with retaining rings. The retaining rings must be located at 120°, the end of the retaining ring must enter the locking cracker. Put the sleeve on the synchronizer hub.
14. Install the synchronizer assembly onto the shaft, with the end of the sleeve with the teeth facing the gear. Before fully installing the hub, rotate the 2nd gear synchronizer ring so that the grooves in it are aligned with the locking crackers in the synchronizer assembly.
15. Install the retaining ring against the synchronizer hub and, pressing the hub as much as possible, measure the gap between the hub and the retaining ring (Fig. 6.36). The gap should be 0-0.04 mm and preferably closer to the lower value. If the gap exceeds the upper limit, install a new retaining ring of suitable thickness. Thicknesses can be 1.50, 1.55 and 1.60 mm.
16. Install the 1st gear synchronizer ring, aligning the grooves with the locking crackers in the synchronizer assembly.
17. Lubricate the needle bearing of the 1st gear with transmission oil, install it on the shaft, then install the 1st gear.
18. Measure the distance between the teeth on the synchronizer locking ring and the timing teeth on the gear as described in step 12 and install a new synchronizer ring if the gap exceeds 0.5 mm.
19. Place the inner bearing ring onto the end of the shaft.
