Audi Workshop Service and Repair Manuals

Removing gearbox   Note t  All cable ties which are released or cut open when removing the gearbox must be refitted in the same positions when installing the gearbox. t  Pay attention to the repair instructions, particularly with regard to contact corrosion → Chapter. –  First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding. –  Disconnect earth strap on battery (in luggage compartment) with ignition switched off. Remove bonnet as follows: –  Release service flap from inside.

–  Release bonnet -arrows- and pull it forwards slightly.

–  Fit Audi A2 engine cover protector -VAS 6011- over bonnet.   Note Do not store bonnet in upright position.

–  Remove the bonnet and lay it down flat on the side with the protective cover. –  Pull rubber seal off plenum chamber. –  Detach wiper arm and scuttle panel trim.

–  Remove both bolts -A- and three hexagon nuts -B-. –  Detach the fresh air intake duct towards the front.

–  Unscrew bolts -arrows- and remove engine cover panel.

–  Detach cable support bracket from gearbox -arrows-.

–  Remove nut -1- and bolt -2- and detach cross brace -A-.

–  Pull locking mechanism on gear selector cable and gate selector cable forwards -arrow 1- onto stop and then turn to left -arrow 2- to lock. –  Pull off securing clip -arrow 3- and remove gate relay lever -A-. –  Remove gearbox selector lever -B- by removing nut -arrow 4-. –  Tie back gear selector cable and gate selector cable.

–  Unbolt slave cylinder -arrows-, detach pipe/hose assembly from retainer on gearbox, move to one side and secure with wire. Do not disconnect pipes.   Note t  Do not depress clutch pedal.

t  Unplug connector from speedometer sender -G22- (-arrow-). –  Remove upper engine/gearbox securing bolts.

–  Remove bracket -A- on starter. –  Then remove upper securing bolt from starter -1-. –  Unplug connector from reversing light switch -F4- (-2-). –  Unplug connector -3- from starter. –  Unscrew wire -4- from solenoid switch, terminal 30.

–  Set up support bracket -10 - 222 A- with adapter -10 - 222 A /13- on wing mounting flanges. –  Partly take up weight of engine/gearbox assembly via the spindles. –  Loosen bolts for left front wheel. –  Raise vehicle. –  Remove left wheel.

–  Remove noise insulation -arrows-.

–  Unscrew earth wire -B- from bottom securing bolt on starter. –  Remove bottom securing bolt -5- from starter and take out starter.

–  Remove heat shield -arrows- for drive shaft. –  Unbolt drive shafts from gearbox flange shafts. –  Lift up drive shaft (right-side) and secure in position. Take care not to damage protective coating.

–  Remove small cover plate -A- for flywheel behind right-hand flange shaft -arrows-.

–  Remove pendulum support -arrows-.

–  Release coupling rod (left-side) -1- from anti-roll bar. –  Detach suspension link (left-side) from wheel bearing housing -arrow- → Rep. Gr.40. –  Remove wheel housing liner from wheel housing (left-side). –  Swivel wheel bearing housing outwards. –  Guide drive shaft (left-side) out between subframe and gearbox. –  Guide drive shaft into wheel housing and secure to suspension strut with wire or similar.

–  Remove hexagon bolts -arrows- at left mounting from gearbox mounting. –  Tilt engine/gearbox assembly; for this purpose, lower via spindle of support bracket -10 - 222 A-.

–  Lower engine/gearbox assembly only until exhaust pipe -1- makes contact with heat shield -2- above subframe -arrow-.   Note The flexible pipe connection (de-coupling element) of exhaust system must not be bent more than 10° - otherwise it can be damaged.

l  Bolts -arrows- securing gearbox bracket -A- must be accessible. –  Detach gearbox bracket -A--arrows-. –  Assemble gearbox jack with gearbox support -3282-, adjustment plate -3282/8- for “02A” gearbox and support elements as follows: –  Place adjustment plate -3282/8- on gearbox support -3282-. (Adjustment plate -3282/8- can only be fitted in one position.) –  Align arms of gearbox support according to holes in adjustment plate -3282/8-.

–  Bolt on support elements -A-, as illustrated on adjustment plate -3282/8-.

–  Place engine and gearbox jack under vehicle; arrow symbol -B- ( → Anchor) on adjustment plate -3282/8- points to front of vehicle. –  Align adjustment plate -3282/8- parallel to gearbox and lock safety support on gearbox. –  Remove bottom engine/gearbox connecting bolts.

–  Push the gearbox off the dowel sleeves and swing carefully towards the subframe. –  Swivel gearbox slightly downwards in vicinity of differential.

–  Then lower gearbox carefully, guiding right-hand flange shaft -A- past flywheel as illustrated and left-hand flange shaft -B- past subframe. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-. Transporting gearbox

–  Bolt gearbox lifting tackle -3336- to clutch housing.

–  Set support arm on sliding bracket by means of locking pin -arrow-. Number of holes visible = 5 –  Take up gearbox with workshop hoist and gearbox lifting tackle -3336-. –  Set down gearbox as required (for example in transport container).