2. Clamp the output shaft in a vise on the visible part between the 3rd and 4th gears.
3. Using an extractor, remove the bearing inner race from the Poi gear.
4. Remove the 1st gear needle bearing.
5. Remove the 1st gear synchronizer ring, install it on the gear.
6. Remove the retaining ring located against 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 2nd gear needle assembly, 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, contact your Audi dealer.
10. Start assembly with the large bearing inner race, 4th gear, circlip, 3rd gear and circlip on the shaft as follows.
11. Lubricate the needle bearing of the 2nd gear with gear 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 the three locking lugs into the grooves in the hub, secure them with circlips. Retaining rings must be spaced at 120°intervals, the end of the retaining ring must fit into the blocking cotter. Slide the sleeve onto the synchronizer hub.
14. Install the synchronizer assembly on the shaft, the end of the sleeve with the teeth must face the gear. Before fully installing the hub, rotate the 2nd gear synchro ring so that the grooves in it line up with the locking cotters in the synchro assembly.
15. Install the retaining ring against the synchronizer hub and, pressing the hub as far as possible, measure the gap between the hub and the retaining ring (Pic. 6.36). The gap should be 0-0.04 mm and preferably closer to the lower value. If the clearance exceeds the upper limit, install a new circlip of suitable thickness. Thicknesses can be 1.50, 1.55 and 1.60 mm.
16. Install the 1st gear synchronizer ring, aligning the slots with the locking cotters in the synchronizer assembly.
17. Lubricate the needle bearing of the 1st gear with gear oil, install it on the shaft, then install the 1st gear.
18. Measure the distance between the teeth on the synchronizer blocking ring and the timing teeth on the gear as described in paragraph 12 and install a new synchronizer ring if the gap exceeds 0.5 mm.
19. Slide the bearing inner race onto the end of the shaft.
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