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DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSAUDI2009A6 BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 20 (5-SPEED MANUAL TRANSMISSION 01A)35 MANUAL TRANSMISSION - GEARS, SHAFTSINPUT SHAFT, DISASSEMBLING AND ASSEMBLINGNOTES

2009 Audi A6 Base

Input shaft, disassembling and assembling: Notes

2009 Audi A6 BaseSECTION Notes

WARNING: This page is about a different car, the 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Input Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

VW 295 Mandrel
VW 295 A Adapter
VW 401 Pressure plate
VW 402 Pressure plate

VW 407 Press tool
VW 408 A Press tool

Fig 2: Identifying Special Tools - Input Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 415 A Tubular section
VW 416 B Tubular section
VW 447 i Thrust pad
VW 771 Multi-purpose tool

30-100 Press tube
40-105 Thrust plate

Fig 3: Identifying Special Tools - Input Shaft, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 222 A Mandrel
30-24 Mandrel
40-202 Pressing-out element
1 - Kukko 21/4 Internal puller

3 - Kukko 17/2 Separating tool

NOTE:

Fig 4: Input Shaft, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Observe technical data when installing new gear wheels or the input shaft. Refer to Code letters, assignment of mechanical units, transmission ratios and capacities .
Replacing components -items 2, 4 and 6 → Input shaft, disassembling and assembling influences the position of the ball bearing. In this case, input shaft must be re-adjusted. Refer to Input shaft, adjusting .

1 - Circlip

Mark
Installation position Installation position of circlips - item 1
Determining thickness. Refer to Adjusting input shaft: Refer to Input shaft, adjusting

2 - Ball bearing

Removing and installing. Refer to Ball bearing for input shaft, multi-function sensor, pinion, selector rods, transmission cover and Torsen differential housing, removing and installing

3 - Circlip

Mark
Installation position Installation position of circlips - item 2
Determining thickness. Refer to Adjusting input shaft: Refer to Input shaft, adjusting

Fig 5: Input Shaft, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

4 - Transmission housing

5 - Needle bearing

Secured with bolt. See Locking bolt for needle bearing
Extracting. See Extracting needle bearing
Installation position. See Installation position of needle bearing
Pressing in. See Pressing in needle bearing

6 - Input shaft

With oiling sleeve
Driving in oiling sleeve. See Driving oiling sleeve into input shaft
Adjusting. Refer to Input shaft, adjusting

7 - Needle bearing for 3rd gear

8 - Sliding gear for 3rd gear

Fig 6: Input Shaft, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

9 - Spring

Inserting in 3rd gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

10 - 3rd gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

11 - Circlip

Mark
Installation position Installation position of circlips - item 3

12 - 3rd and 4th gear synchro-hub

High collar faces 3rd gear
Pressing off. See Pressing out 3rd and 4th gear synchro-hub
Pressing on. See Pressing on 3rd and 4th gear synchro-hub

13 - Circlip

Mark
Installation position Installation position of circlips - item 4
Re-determine when replacing synchro-hub. See Determining circlip

Fig 7: Input Shaft, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

14 - 3rd and 4th gear locking collar

Installation position. See Installation position of locking collar

15 - 4th gear synchro-ring

Checking for wear. See Checking synchro-ring for wear

16 - Spring

Inserting in 4th gear sliding gear. See Inserting spring into sliding gear
Assignment to sliding gear

17 - 4th gear sliding gear

18 - 4th gear needle bearing

19 - 5th gear wheel

Pressing off. See Pressing out 5th gear wheel
Pressing on. See Pressing on 5th gear wheel

20 - Circlip

Mark
Installation position Installation position of circlips - item 5
Re-determine when replacing 5th gear wheel. See Determining circlip

Fig 8: Input Shaft, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

21 - Roller sleeve

Replace
Is damaged on removal
Extracting. See Extracting roller sleeve
Installation position. See Installation position of roller sleeve

Driving in. See Driving in roller sleeve

22 - Sleeve

Plastic

23 - Transmission cover

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.