Audi Workshop Service and Repair Manuals

Removing gearbox (vehicles with 2.0 ltr. TDI engine)

Special tools and workshop equipment required

t	Adapter -VW 771/40-

t	Support bracket -10 - 222 A-

t	Hook -10 - 222 A /10-

t	Adapter -10 - 222 A /19-

t	Removal lever -80 - 200-

t	Hose clamps, up to 25 mm -3094-

t	Gearbox support -3282-

t	Pin -3282/29-

t	Adjustment plate -3282/33-

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

t	Engine bung set -VAS 6122-

t	Engine support bracket, basic set -T40091-

t  Engine support bracket, supplementary set -T40093- t  Bolt M10x20

Procedure –  Remove engine cover panel -arrows-.   Note Re-attach all cable ties at the same locations when re-installing.

–  Remove air cleaner housing → Injection and glow plug system; Rep. gr.23.

–  Remove starter → Electrical system; Rep. gr.27.

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

–  Remove subframe → Running gear; Rep. gr.40. –  Remove flange shaft (right-side) → Chapter. –  Unbolt drive shaft (left-side) from flange shaft on gearbox → Running gear, front-wheel drive; Rep. gr.40.

–  Remove securing clips -1, 2-. –  Move gear selector cable and gate selector cable clear. –  Remove securing clip -3- and detach gate relay lever.

–  Unscrew bolts and nut -arrows-, remove cable support bracket and place to one side together with cables.

–  Vehicles with plastic pipe between clutch master and slave cylinders: clamp off supply hose at brake fluid reservoir using hose clamp -3094-.

–  Vehicles with pipe/hose assembly between clutch master and slave cylinders: clamp off hose -A- on pipe/hose assembly using hose clamp -3094-. –  Pull clip -arrow- out as far as stop. –  Pull plastic pipe or pipe/hose assembly -A- out of bleeder connection.   Note -Item B- can be disregarded. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Press release tabs and disconnect crankcase breather hose -1-. –  Remove bolt -2-, swivel air pipe and connection to rear and detach from turbocharger.   Note -Item 3- can be disregarded.

–  Vehicles with start/stop system: unplug electrical connector -4- from gearbox neutral position sender -G701-. –  Unplug electrical connector -3- at reversing light switch -F4-.   Note -Items 1 and 2- can be disregarded.

–  Remove nuts -1- and bolt -3- and press electronics box -2- to one side.

–  Remove bolts -arrows-. –  Move electrical wiring and hoses clear at air pipe (left-side) using removal lever -80 - 200-. –  Release hose clip -3- and detach air pipe (left-side).

–  Remove vacuum hose -arrow 1- (leading to brake servo) together with grommet -arrow 2-.

–  Remove bolts -1- (accessible from above).   Note Other items can be disregarded.

Vehicles without air conditioner: –  Set up support bracket -10 - 222 A- on wing mounting flanges, as shown in illustration. –  Engage hook of -10 - 222 A /10- in engine lifting eye (rear left).

–  Attach remaining parts of support bracket as shown in illustration.

–  Attach remaining parts of support bracket as shown in illustration. –  Engage hook of spindle -10 - 222 A /11- in engine lifting eye (front left). –  Pre-tension hook -10 - 222 A /10- and spindle -10 - 222 A /11-.

Vehicles with air conditioner: –  Remove bumper cover → General body repairs, exterior; Rep. gr.63. –  Set up support bracket -10 - 222 A- on top edges of body flanges (left and right) and on impact bar, as shown in illustration. –  Attach hooks of spindles -10 - 222 A /11- to engine lifting eyes. –  Apply light tension to spindles.

Continued for all vehicles: –  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 support and gearbox mounting. l  Dimension -a- = 100 mm … 110 mm.

–  Remove bolts -arrows- and detach gearbox support. To remove gearbox „0A8“, set up gearbox support -3282- with adjustment plate -3282/33-. –  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. –  In place of support element -C-, screw in pin -3282/29-. –  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 -3282/33- parallel with gearbox.

–  Remove bolt -C- securing gearbox to engine. –  Secure adapter -VW 771/40- to threaded hole in gearbox housing, as shown in illustration. –  Secure gearbox to gearbox support -3282- with bolt M10x20 -item A-. l  Pin -B- should be flush with underside of guide of gearbox support -3282--arrow-. –  Support gearbox from underneath by raising engine and gearbox jack -V.A.G 1383 A-.

–  Remove remaining engine/gearbox securing bolts -3, 4-. –  Press gearbox off dowel sleeves. –  Pull gearbox off engine. –  Lift engine slightly with spindles and push towards right side of vehicle, paying attention to refrigerant lines. –  Carefully lower gearbox using engine and gearbox jack -V.A.G 1383 A-. –  While lowering gearbox, change position of gearbox using spindles on gearbox support -3282-.   Note

When installing a replacement gearbox, the gearbox selector lever and the gate relay lever have to be transferred from the old gearbox to the new one → Chapter.