Audi Workshop Service and Repair Manuals

Installing gearbox Installation is carried out in reverse sequence; note the following: Please note the information in the table below - „Checking gear oil level and filling up with gear oil“.

„Checking gear oil level and filling up with gear oil“
		»No«	»Yes«	»Yes«
Gearbox	Replacement unit	X
	No oil escaping	X
	Was completely dismantled		X Before installing → Item Oil capacity → Chapter
	Was partially dismantled l  (gearbox housing and clutch housing were not separated)			X After installing → Chapter

Note t  The special tools required are listed in the procedure for → Chapter „Removing gearbox“. t  Renew self-locking nuts and bolts when performing assembly work. t  Renew oil seals and gaskets, and bolts which are tightened by turning through a specified angle. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Re-attach all cable ties at the same locations when re-installing. t  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

–  Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves -arrows-. –  Check clutch release bearing for wear and renew if necessary. –  Lubricate surface which contacts ball-head pin with grease for clutch plate splines -G 000 100-.

–  Incline gearbox via spindles of gearbox support -3282-. l  The differential must face upwards. l  Pivot gearbox downwards in area of 6th gear. –  Then raise gearbox carefully.

–  Guide gearbox with differential past subframe -A- and swivel in direction of -arrow-. –  Make sure longitudinal member -B- is not in the way.

l  Guide flange shaft (right-side) -1- past recess -arrow- in intermediate plate. –  Align gearbox with engine in installation position and install. –  Bolt gearbox onto engine. Tightening torques → Anchor –  Detach gearbox jack with gearbox support -3282- from gearbox after bolting gearbox to engine. –  Remove engine support -3300 A- and support -T10036-. –  Install starter → Electrical system; Rep. gr.27.

–  Secure gearbox bracket -A- to gearbox with new bolts -arrows-. Tightening torque → Item –  Pull gearbox up to support arm of gearbox mounting with spindle on support bracket -10 - 222 A-.

–  Align engine/gearbox in installation position. To do so, raise engine/gearbox until gearbox bracket makes full contact with gearbox mounting.   Caution The threads in the gearbox bracket can be damaged if the bolts are not inserted straight. Before fitting the bolts -arrows-, the gearbox bracket and the support arm of the gearbox mounting must be aligned absolutely parallel. If necessary, press rear part of gearbox up with engine and gearbox jack. –  Use new bolts -arrows- to secure gearbox mounting to gearbox bracket. Tightening torque → Item   WARNING Do not remove support bracket -10 - 222 A- until all bolts securing the left-hand engine/gearbox mounting have been tightened to the specified torque. –  Check mountings of engine/gearbox assembly for correct adjustment → Engine, mechanics; Rep. gr.10.

–  Fit pendulum support with new bolts -1 … 3- in accordance with installation instructions → Anchor. Tightening torques → Chapter

–  Secure catalytic converter to turbocharger -arrows- → Engine, mechanics; Rep. gr.26.   Note -Item 1- and -item 2- can be disregarded.

–  Install radiator cowl -arrows- and attach electrical connector -1-.

–  Install air intake hose. Make sure retaining clip -arrow- snaps onto retaining lug -A-. –  Secure drive shafts to flange shafts on gearbox → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  Secure heat shield for drive shaft (right-side) to engine.

–  Install clutch slave cylinder -arrows-. Tightening torque → Item –  Install gearbox support -1-. Tightening torque → Item

–  Gearbox for vehicles with start/stop system: plug connector -arrow- into gearbox neutral position sender -G701-.

–  Plug in electrical connector -arrow- at reversing light switch -F4-. –  Connect earth strap at upper engine/gearbox securing bolt.

Metal gate relay lever -B-:   Note To install, lubricate bearings and moving surfaces with grease -G 000 450 02-. –  Install gearbox selector lever -A- → Fig.. –  Tighten hexagon nut -arrow 4- to specified torque → Item. –  Fit gate relay lever -B- and secure with securing clip -arrow 3-. –  Attach gear selector cable to gearbox selector lever and secure with securing clip -arrow 1-. –  Attach gate selector cable to gate relay lever and secure with securing clip -arrow 2-.

Plastic gate relay lever: –  Insert gate relay lever with cable end-piece as far as stop. l  Gate relay lever is secured by detent -arrow 1-. l  Ensure that components engage securely. l  Cable end-piece must be behind detent -arrow 2-.   Note From 08.2008 onwards the gate relay lever is secured with a clip → Fig..

Continued for all vehicles: –  Secure cable support bracket -arrows-. Tightening torque → Item –  Fit bracket -B- to gearbox. –  Push pipe/hose assembly -A- into bracket -B- on gearbox. –  Adjust selector mechanism → Chapter.

–  Install battery tray -arrows- and battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Rep. gr.24. –  Install engine cover panel → Engine, mechanics; Rep. gr.10.

–  Install front section of wheel housing liner (left-side) → General body repairs, exterior; Rep. gr.66. –  Fit front left wheel → Rep. gr.44.

Audi A3 –  Install noise insulation (centre) -1 and 2- → General body repairs, exterior; Rep. gr.50.

Audi A3 Cabriolet –  Install noise insulation frame -arrow- → General body repairs, exterior; Rep. gr.50.

–  Install noise insulation (centre) -1- → General body repairs, exterior; Rep. gr.50.

Tightening torques Engine/gearbox attachment (1.8 ltr. TFSI engine)

Item	Bolt	Nm
1, 2	M12 x 65	80
3 1)2)	M12 x 150	80
4 1)2)	M12 x 165	80
5	M10 x 50	40
6	M12 x 85	80
A	Dowel sleeves for centralising
l  1) Bolt with stud M8. l  2) Also starter to gearbox

Component	Nm
Clutch pipe bracket to gearbox	20
Bracket for electrical wiring at bottom starter bolt	23
Heat shield for drive shaft to cylinder block	25