Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Hose clamps, up to Ø 25 mm -3094- (3x)

t	Hooks -3004- (3x)

t	Gearbox support -3282-

t	Adjustment plate -3282/27-

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

t	Chain (2x)

Procedure   Note All cable ties which are released or cut open when removing the gearbox must be refitted in the same position when installing the gearbox. –  Move gear lever to neutral.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27. –  With ignition switched off, disconnect earth wire at battery.

–  Remove engine cover panel -1- above cylinder head cover -arrows-.

–  Detach air intake hose at throttle valve module -J338- (slacken hose clip -4-). –  Unplug electrical connector for air mass meter -G70--1-. –  If fitted, detach hose -5- from air cleaner housing. –  Remove bolts -2- and -3-. –  Take out air cleaner housing.

–  Remove battery and battery tray -arrows-.

–  Detach cable support bracket from gearbox -arrows-.

–  Detach securing clip -arrow 2- and remove relay lever -A- with gate selector cable.   Caution Do not remove cable end-pieces from selector shaft lever or relay lever. Cable end-pieces must be renewed after removal. –  Unscrew nut -arrow 1- for pressure pipe of power steering. –  Unscrew nut -arrow 3- and detach selector shaft lever -B- with gear selector cable.   Note If necessary, use puller -Kukko 20-10- to detach. –  Tie up gear selector cable with selector shaft lever and gate selector cable.

–  Unplug electrical connector at speedometer sender -G22--arrow-.

–  Unscrew earth wire -1-. –  Detach electrical connector -3- from starter. Pipe -4- remains connected. –  Unplug connector -2- and pull out of bracket. –  Disengage wiring from bracket on starter and move clear to one side. –  Remove bracket. –  Remove top bolt securing starter. –  Unscrew engine/gearbox securing bolts which are accessible from above.

Vehicles with two charge air coolers:   Note Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it. –  Move tensioner in direction of -arrow- to slacken poly V-belt. –  Detach poly V-belt.

Vehicles with one charge air cooler: –  Remove both front wheels. –  Detach air pipe leading to charge air cooler at longitudinal member (bottom right) -arrows-.

Continued for all vehicles: –  Remove centre noise insulation -arrows-.

–  Remove noise insulation (left-side) -arrows-.

–  Remove noise insulation (right-side) -arrows-.

Vehicles with two charge air coolers: –  Remove tubular cross member -arrows-.

–  Remove power steering pump pulley (counterhold with Allen key).

Continued for all vehicles: –  Clamp off supply hose and pressure hose at power steering pump using hose clamps -3094-. –  Unplug electrical connector -1- on power steering pressure switch. –  Unscrew pressure pipe -2- on power steering pump.

–  Detach power steering pipe from gearbox -arrows- and remove speed nut from gearbox.   Note If fitted, detach additional pipe retainer. –  Remove bottom bolt securing starter and take out starter.

–  Using hose clamp -3094-, clamp off pressure line to clutch slave cylinder. –  Pull up retaining clip -arrow- and pull pressure line -1- out of hose connection.   Caution Do not operate clutch pedal after disconnecting pressure line from slave cylinder.

–  If fitted, detach cross piece -3- from subframe -1-. –  Unplug electrical connector for reversing light switch -F4--2-.

–  Disconnect exhaust system at clamp -arrows-. –  Push clamp towards the rear.

–  Tie up exhaust system with a chain. To do so, engage hooks -3004- in openings on underbody (if necessary remove plugs).   Note The flexible joint (de-coupling element) in the exhaust system must not be bent more than 10° – otherwise it can be damaged.

–  Mark position of propshaft relative to flexible coupling on bevel box. –  Unscrew propshaft from flexible coupling at bevel box -arrows-.   Note Counterhold with a lever on triangle flange when loosening the bolts. –  Press propshaft horizontally to rear as far as possible.   Note

After loosening bolts -A- (⇒ following illustration N34-0712) the engine/gearbox assembly will swing slightly to the front.   Caution Make sure that the seal -arrow- in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed.

–  First unscrew bolts -A- and then bolts -B- and remove pendulum support. –  Carefully press engine/gearbox assembly forwards.

–  If fitted, unbolt front bracket for exhaust system -arrow- from subframe. –  Remove bolts -2- for steering box. –  Lever off steering box from subframe (dowel sleeve). –  Position engine and gearbox jack -V.A.G 1383 A- with engine and universal support -V.A.G 1359/2- below subframe. –  Remove subframe bolts -1- and -3-. –  Carefully lower subframe and press steering box upwards at the same time (do not detach subframe from swivel joints and coupling rods). –  Tie up steering box. –  Remove drive shafts from gearbox flange shafts and place to rear onto subframe (take care not to damage surface protection).

–  Use chain to tie subframe to rear (engage hook -3004- into opening on underbody; if fitted, remove plug).

–  Unscrew heat shield for drive shaft on right of bevel box -arrows-.

Vehicles with bevel box bracket (metal casting): –  Unscrew bolts -A ... C- at bevel box bracket.   Note It is not possible to remove bracket at this stage. Bracket remains in installation position.

Vehicles with bevel box bracket (sheet metal version): –  Remove bolts -A ... C- and take off bevel box bracket.

Continued for all vehicles:   Note The small cover plate -2- is fitted behind the bevel box and is not visible with bevel box installed. Shown in illustration with gearbox removed. –  Remove bolt -1- (using 10 mm spanner) and remove flywheel cover plate behind bevel box.

–  Set up support bracket -10-222 A- with rack -10-222 A/1- on wing mounting flanges -arrows-. –  Take up weight of engine/gearbox assembly via the spindle.

–  Remove gearbox support (left-side), to do so unscrew bolts -1- and -2-.

–  Lower the engine/gearbox assembly slightly using the spindle.

l  The distance -a- between gearbox housing and gearbox mounting should be 100 ... 110 mm.

To remove manual gearbox 02M set up gearbox support -3282- with adjustment plate -3282/27-. A -  Support elements B -  Arrow points in direction of travel –  Assemble engine and gearbox jack -V.A.G 1383 A- as follows: –  Place adjustment plate -3282/27- on gearbox support -3282- (adjustment plate only fits in one position). –  Attach support elements as illustrated on adjustment plate.

–  Align arms of gearbox support according to holes in adjustment plate -3282/27-. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle; arrow symbol on the adjustment plate faces forward. –  Align the adjustment plate parallel to the gearbox. –  Secure support element to gearbox with bolt M8x25 -arrow-.

–  Unscrew bolt -arrow- above bevel box.

–  Unscrew engine/gearbox securing bolts which are accessible from below. –  Pull gearbox off dowel sleeves. –  Remove bevel box bracket. –  Pull the gearbox off engine first from the bevel box side and then from the front side. –  Lower gearbox carefully.