Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Gearbox support -3282-

t	Pin -3282/29-

t	Adjustment plate -3282/39-

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

t  Press tool -T10148-

t  Spindle from assembly device -3066- or M8 x 105 bolt t  Grease for clutch plate splines -G 000 100-   Note All cable ties which are released or cut open during removal must be fitted in the same position when installing.   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery → Electrical system; Rep. gr.27.

–  Press release tab -arrow- and remove cover -1- over battery.

–  With ignition switched off, disconnect earth wire -arrow- at battery.

–  Disconnect hose -1- and connector -2- at air cleaner housing. –  Remove bolt -3-. –  Release spring clips -4- and detach air intake hose. –  Take out air cleaner housing. –  Remove battery → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-. –  Detach front of battery tray from air duct.

–  Unplug electrical connectors -1- at starter and -4- at reversing light switch -F4-. –  Unscrew wire -2- at starter and earth wire -3-. –  Move wiring clear. –  Remove top starter mounting bolt.

–  Detach cable support bracket from gearbox -arrows-. –  Remove bracket -B- from gearbox and disconnect from pipe/hose assembly -A-.

Metal gate relay lever -B-: –  Detach securing clip -arrow 1- from gearbox selector lever -A- and pull off gear selector cable. –  Detach securing clip -arrow 2- from gate relay lever -B- and pull off gate selector cable. –  Pull off securing clip -arrow 3- and remove gate relay lever -B-.

Plastic gate relay lever –  Detach securing clip -arrow 1- and pull off gear selector cable. –  Detach gate selector cable from cable end-piece → Anchor. –  Press detent -arrow 2- down onto stop and remove gate relay lever together with cable end-piece. Move gate relay lever in normal direction of operation.   Note From 08.2008 onwards the gate relay lever is secured with a clip → Fig.. Continued for all vehicles: –  Tie cables with cable support bracket to one side. –  Remove nut -arrow 3- and detach gearbox selector lever -A-.

–  Remove gearbox support -arrows A-. –  Remove clutch slave cylinder -arrows B-, move to one side and secure with wire. Do not disconnect pipes.   WARNING Do not depress clutch pedal after removing slave cylinder. –  Remove upper engine/gearbox securing bolts.

–  Remove engine cover panel -arrows-.

–  Position support bracket -10 - 222 A- on wing mounting flanges with adapters -10 - 222 A /3-. Spindles face to the front. –  Take up weight of engine evenly with both spindles; do not lift. –  Raise vehicle. –  Remove front left wheel. –  Turn steering to the left.

–  Remove centre noise insulation (fasteners -1 ... 3-).

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

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

–  Remove nut -2- and detach bracket -1- from stud together with electrical wiring. –  Remove bottom starter mounting bolt and take out starter.

–  Unbolt heat shield for right-side drive shaft -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts. –  Lift drive shafts as far as possible and tie in place. Do not damage surface coating.   Note The left drive shaft should be tied up as far forward as possible.

–  Unbolt support bracket for exhaust system -arrows-.

–  Remove bolts -1 ... 3- and detach pendulum support.

–  Remove hexagon bolts -arrows- at left mounting from gearbox mounting.

–  Adjust spindles of support bracket -10 - 222 A- to lower gearbox by distance -a-. l  Dimension -a- = 50 mm

–  Unbolt gearbox bracket -A- from gearbox -arrows-.

–  Remove bolts -A- and -B- and take out strut -1-.

–  Remove securing bolt -arrow- for flange shaft. To do this, screw two bolts into flange and counterhold flange shaft with suitable lever.   Note Before removing flange shaft, check oil seal for damage. A leaking oil seal must be renewed when fitting flange shaft. –  Pull out flange shaft and spring.

–  Screw spindle -A- of assembly device -3066- into threaded piece in differential. –  Insert thrust piece -T10148- and secure with nut -B-.   Note t  The thrust piece -T10148- serves to protect the oil seal (right-side) and the gearbox from dirt. t  Instead of using the spindle -A-, an M8 x 105 mm bolt can also be screwed hand-tight into the threaded piece in the differential. To remove gearbox „02S“, set up gearbox support -3282- with adjustment plate -3282/39-. –  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- and -C-, as illustrated on adjustment plate. –  Place engine and gearbox jack -V.A.G 1383 A- under vehicle; arrow symbol -B- on adjustment plate points to front of vehicle.

–  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove bottom engine/gearbox connecting bolts.

–  Carefully pull gearbox off dowel sleeves. t  Distance between gearbox and engine is slightly greater at the front than at the back.

–  Push gearbox forwards slightly and bring it into the position shown. –  Lower gearbox out of vehicle. When removing gearbox, ensure sufficient clearance between sleeve -1- and pressure plate -arrow- to prevent damage.   Note

If you will be installing a new gearbox instead of the one removed, re-install flange shaft and tighten countersunk bolt -arrow-. Tightening torque → Item