Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adapter -10 - 222 A /3-

t	Shackle -10 - 222 A /12-

t	Adapter -10 - 222 A /13-

t	Transportation shackle -T40016-

t	Protective cover for bonnet Audi A2 -VAS 6011-

t	Gearbox support -3282-

t	Adjustment plate -3282/28-

t	Pin -3282/29-

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

t	Hose clip pliers -V.A.G 1921-

Procedure   Note Pay attention to the repair instructions, particularly with regard to contact corrosion → Chapter.   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Disconnect the earth wire at the battery → Rep. gr.27.

–  Wash and polish outside of bonnet with a chamois leather. –  Release service flap from inside. –  Release the bonnet -arrows- and pull it forwards slightly.

–  Fit the protective cover -VAS 6011- over the bonnet.   Note

Do not store the bonnet in an upright position. –  Detach the bonnet and set it down on the protective cover -VAS 6011-.

–  Use a screwdriver to prise the caps -3- and -4- off the wiper arms. –  Unfasten the nuts of both wiper arms by several turns. –  By tilting slightly, consecutively detach the wiper arms -1- and -2- from the wiper shaft. –  Completely unfasten the nuts and detach the wiper arms.

–  Disconnect the washer fluid pipe -3-. –  If fitted, unplug the connectors -4- and -5- for the heated washer jets. –  Unfasten the hose clamp -6- with the hose clamp fitting tool -V.A.G 1921- and detach the water drain hose from the cowl panel grille. –  Detach the rubber seal -1- for the cowl panel grille. –  Detach the cowl panel grille -2-. –  Move washer fluid pipe clear.

–  Remove nuts and bolts -arrows-. –  Pull the fresh air duct forwards and swivel it out to the right side of the vehicle.

–  Remove engine cover panel -arrows-. –  Remove the noise insulation underneath. This involves detaching the crankcase breather hose. –  Remove hydraulic control unit → Chapter.

–  Remove the bolt -1- at the top of the gear actuator heat shield -2-.

–  Unplug the connector -arrow- at the vehicle speed sender -G68-.

–  Unplug the connector -arrow- for the gearbox speed sender -G38-.

–  Unfasten the lock nut -B- and the adjusting nut at the clutch cable. –  Disengage the clutch cable at the operating lever.   Note Do not unfasten the hydraulic pipe at the clutch slave cylinder. –  Disengage the wire clip at the location marked with an -arrow- and pull the clutch slave cylinder out of the support bracket -A-. –  Lay aside the clutch slave cylinder (do not open up the piping system). –  Unscrew the wire clip from the gearbox. –  Detach all other brackets and wiring from gearbox.

–  Remove front wheels. –  Remove the noise insulation -arrows-.

–  Unscrew the right drive shaft heat shield -arrow-. –  Remove drive shafts on both sides → Rep. gr.40.

–  Sever the cable tie -2- and lift the cover -3- off the solenoid switch -1-.

–  Unscrew the nut -2-. –  Detach the wire -3- from the starter solenoid switch. –  Disengage the wire holder. –  Remove the bolt for the starter at the top. –  Unscrew the nut -1- and detach the earth wire from the starter at the bottom. –  Unplug the connector/terminal 50 -Item 4- at the solenoid switch. –  Remove the centre hex stud at the bottom and take out the starter downwards. –  Unplug connector -5- at reversing light switch -F4- and move wiring clear.

–  Unscrew the starter catalytic converter at the turbocharger -arrows- and secure at the bulkhead → Rep. gr.26.

–  Remove the bolts -3- and detach the gear actuator heat shield -2-.   Note

Do not unfasten the hydraulic pipes at the gear actuator. –  Slacken off the bolt -1- by a few turns. –  Detach the selector finger -A- from the gearbox selector rod. –  Remove bolts -2- and -3-. –  Tie the gear actuator in place at the body as far as possible.

–  Remove the bolts -1, 3-, unscrew the nut -2- and detach the pendulum support.

–  Vehicles with power steering: disconnect hydraulic lines -1- and -2- from steering box → Rep. gr.48.

–  Remove both bolts connecting the engine to the gearbox at the top. –  Screw on the transportation strap -T40016/1- at the rear left of the cylinder head.

–  Fit the adapter -10 - 222 A /3- at the support bar -10 - 222 A-. –  Set up support bracket -10 - 222 A- with adapter -10 - 222 A/ 13- on wing mounting flanges.   Note Engage the adapters -10 - 222 A/ 13- at the rear in the mounting hooks for the bonnet -arrow-. –  Slightly pre-tension the engine/gearbox assembly by way of the spindles.

–  Remove the left gearbox mounting bolts -arrows-. –  Carefully tilt the engine/gearbox assembly. To do so, screw down the left spindle at the support bar -10 - 222 A-.

–  Remove bolts -A- and detach gearbox bracket -B-.

The gearbox support -3282- is set up for removal of the gearbox „085 DS“ using the adjustment plate -3282/28-. –  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. –  Screw in the support element -A- as shown on the adjustment plate. –  In place of the support element -C-, screw in the pins -3282/29-. –  Position the engine and gearbox lifter under the vehicle. l  The arrow symbol -B- on the adjustment plate points in the direction of travel.

–  Align adjustment plate -3282/28- parallel with gearbox.

–  Screw the pins -3282/29--arrows- into the holes for the pendulum support bolts at the gearbox.

–  Remove the bolts -1- and -2- connecting the engine to the gearbox at the bottom. –  Press the gearbox off the dowel sleeves and tilt on the left by way of the spindles of the gearbox support -3282-. –  Carefully lower gearbox using engine and gearbox jack -V.A.G 1383 A-. –  Alter the position of the gearbox in the area of the subframe and the body on the left when lowering by way of the spindles of the gearbox support.