Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/31-

t	Engine and gearbox jack -V.A.G 1383 A-

t  Removal lever -80 - 200-

t  Engine support -3300 A-

t  Support plate -T10413-

Procedure   Note Re-attach all cable ties at the same locations when re-installing. –  Release catches -arrows- and detach air duct -1-.

–  Release hose clip -1- and disconnect air hose from connection. –  Detach vacuum hose -arrow- from air hose. –  Remove bolt -3- and detach air cleaner housing.   Note -Item 2- can be disregarded.

–  Move clear coolant hose -1-. –  Unscrew bolts -arrows- and detach engine cover panel.   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery.

–  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27.

–  Remove securing clip -1-. –  Detach gear selector cable from gearbox selector lever -B-. –  Remove gate relay lever -A- from gearbox together with cable end-piece → Fig.. –  Remove gearbox selector lever -B- by removing nut -arrow 2-.

–  Detach cable support bracket from gearbox -arrows- and tie up.

–  Remove bolts -arrows- and detach clutch slave cylinder -A- with pipe/hose assembly -B- and tie up to one side; do not disconnect pipes.   Caution Risk of irreparable damage to clutch slave cylinder. Do not press clutch pedal after removing clutch slave cylinder.

Vehicles with start/stop system: –  Unplug electrical connector -arrow- from gearbox neutral position sender -G701-. Continued for all vehicles:

–  Detach electrical wires -2- and -3- at starter and move them clear. –  Remove upper securing bolt -1- for starter. –  Remove upper engine/gearbox securing bolts.

–  Detach electrical connector -2- from alternator.   Note -Item 1- and -item 3- can be disregarded.

–  Remove bolts -arrows- and detach heat shield for turbocharger.

–  Unscrew nuts -arrows- for catalytic converter. –  Move electrical wiring harness going to alternator clear at catalytic converter.

–  Lever clips off sealing elements using removal lever -80 - 200- and detach sealing elements on both sides.

–  Set up support bracket -10 - 222 A- on wing mounting flanges, as shown in illustration. l  Position both adapters -10 - 222 A /8- behind lock carrier connection -arrow- and next to bolts -A-. l  Plenum chamber cover -B- will now rest on adapters -10 - 222 A /8-. –  Hook spindle of support bracket into engine lifting eye (left-side). –  Take up weight of engine with spindle; do not lift.

–  Remove nuts -1- and bolt -3- and press electronics box -2- to one side. –  Raise vehicle. –  Remove front left wheel.

–  Remove noise insulation -1- → General body repairs, exterior; Rep. gr.66. –  Remove wheel housing liner (front left) → General body repairs, exterior; Rep. gr.66.

–  Remove radiator cowl → Engine, mechanics; Rep. gr.19.

–  Unplug electrical connector -1- at reversing light switch -F4-. –  Unplug electrical connectors and disengage from bracket -2-. –  Unscrew nut -arrow- and detach bracket -2-. –  Remove starter → Electrical system; Rep. gr.27.

–  Remove bolts -1-. –  Press rubber mountings -2- for exhaust system off pins.

–  Loosen nuts -arrows- and move clamp towards rear. –  Detach catalytic converter and centre silencer downwards.

WARNING Risk of accident. The bolted connection -1- must not be slackened. –  Remove bolts -arrows- and detach pendulum support. –  Unbolt drive shafts (left and right) from flange shafts on gearbox.

–  Remove nuts -arrows- securing swivel joint (left-side). –  Swivel wheel bearing housing (left-side) outwards. At the same time, pull out drive shaft (left-side) between subframe and gearbox. –  Swivel drive shaft (left-side) into wheel housing and secure to suspension strut with cord or similar. Do not damage paint on drive shaft. –  Tie-up drive shaft (right-side) as high as possible with cord or similar. Do not damage paint on drive shaft.

–  Remove bolt -A- securing engine to gearbox above flange shaft (right-side). –  Remove bolts (bottom) securing engine to gearbox.

–  Remove bolts -arrows- from gearbox mounting.

–  Lower engine/gearbox assembly using spindle of support bracket -10 - 222 A- until distance -a- is obtained between gearbox bracket and gearbox mounting. l  Dimension -a- = 50 mm l  Gearbox must not make contact with subframe in area of differential. l  Bolts -arrows- securing gearbox bracket -A- must be accessible.

l  Pay attention to coolant hoses between engine and heat exchanger for heating system. –  Detach gearbox bracket -A- from gearbox -arrows-.

–  Secure support plate -T10413- to subframe -arrow-.

–  Then secure engine support -3300 A- to support plate.   Note Place flat rubber block -arrow- between the two to protect sump. –  Press engine towards front of vehicle by approx. 65 mm using spindle of engine support; note the following:

l  Alternator and air conditioner compressor -2- must not make contact with refrigerant line -1--arrow-.

To remove gearbox „02U“, set up gearbox support -3282- with adjustment plate -3282/31-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate. –  Bolt on support elements -A-, as illustrated on adjustment plate. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. l  The arrow symbol -B- on the adjustment plate points in the direction of travel.

–  Align adjustment plate -3282/31- parallel to gearbox and lock safety support on gearbox. –  Support gearbox from underneath by raising engine and gearbox jack -V.A.G 1383 A-. –  Remove the last engine/gearbox securing bolt -arrow-. –  Pull gearbox off dowel sleeves and slightly away from engine.

–  Then carefully guide gearbox with flange shaft (right-side) -A- past flywheel/intermediate plate -B- as illustrated. –  Then lower gearbox in area of cover for gearbox housing via spindles of gearbox support -3282-.

–  Swivel gearbox out further and lower it carefully, guiding it past motor/pump unit -A- for power steering and subframe -B-. Pay attention to power steering pipes -C-.