Disassembly and assembly of the secondary shaft (Audi 100 C3)

Disassembly

Engage 2nd gear and press the second inner ring of the double-row tapered roller bearing onto the 1st gear pinion.

Press the synchronizer of the 1st and 2nd gears with the 2nd gear.

Remove the 4th gear retaining ring.

Press out the 4th gear pinion.

Press the tapered roller bearing.

Assembly

Install the tapered roller bearing.

Using a press, press the fourth gear pinion with the wide flange towards the main gear pinion until it stops, after heating it on a heating plate to a temperature of 120°C.



Install the 4th gear pinion retaining ring of the thickest thickness from those supplied as spare parts (see subsection "Detailed technical specifications").

Using a press, press the third gear pinion with the wide flange towards the fourth gear pinion until it stops, having first heated it, like the fourth gear pinion, to a temperature of 120°C.

Calculate the thickness of the third gear pinion retaining ring. To do this, measure the gap between the end of the pinion and the shaft flange using a feeler gauge. Install a 1.50 mm thick retaining ring if the measured gap is less than 1.60 mm, and a 1.60 mm thick retaining ring if it is equal to or greater than 1.60 mm.





Check the axial clearance between the ends of the locking rings and the ends of the toothed rims of the synchronizers of the gears of the first and second gears, which should be at least 0.5 mm. If the clearance is smaller, replace the locking rings.

Install the needle bearing and 2nd gear sliding gear on the shaft.

Assemble the sliding sleeve with the hub of the synchronizer of the 1st and 2nd gears, directing the groove of the hub towards the 1st gear pinion.

Install the crackers and put on the springs, placing their connectors every 120' and inserting the curved ends of the springs into the recesses of the crackers.

Using a press, press the synchronizer of the 1st and 2nd gears onto the shaft, directing the groove of the hub towards the 1st gear pinion.

Press on the inner ring of the 1st gear pinion needle bearing, the 1st gear pinion, and the second inner ring of the double-row tapered roller bearing.