Audi Workshop Service and Repair Manuals

Installing gearbox Installation is carried out in reverse sequence; note the following:   Note t  Renew seals, gaskets and self-locking bolts and nuts. t  Renew 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  All cable ties which are released or cut open during removal must be fitted in the same position when 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 -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. t  It should be possible to push the clutch plate back and forth slightly on the input shaft. t  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).

Vehicles with 1.2 ltr. TFSI engine: –  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.

–  Engage intermediate plate at sealing flange -arrow A- and push onto dowel sleeves -arrows B-.

Vehicles with 1.4 ltr. TFSI engine: –  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.

–  Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves -arrows-. Continued for all vehicles: –  Check release bearing for wear and renew if necessary. –  Lubricate surface on release lever which contacts ball-head pin with MoS2 grease.

–  Raise gearbox carefully and move to installation position using gearbox support -3282-. –  When doing this, carefully guide gearbox, as illustrated, past flywheel -arrow 2- and subframe -arrow 1-.

–  Turn gearbox in area of cover for 6th gear upwards as illustrated -arrow 1-. –  Then pivot differential side of gearbox downwards and move gearbox into installation position. l  Gearbox must be aligned parallel to engine. –  Fit gearbox and and tighten bolts -arrows 2-. Tightening torque: vehicles with 1.2 ltr. TFSI engine → Anchor, vehicles with 1.4 ltr. TFSI engine → Anchor.

–  Screw in and tighten engine/gearbox securing bolt -A-. Tightening torque: vehicles with 1.2 ltr. TFSI engine → Anchor, vehicles with 1.4 ltr. TFSI engine → Anchor. –  Remove gearbox support -3282-. –  Bolt gearbox onto engine.

Tightening torques for engine/gearbox connection (1.2 ltr. TFSI engine):

Item	Bolt	Nm
1, 2, 3	M12x60	80
4 1)	M12x55	80
5 2)	M12x150	80
6	M12x70	80
7, 8	M10x30	40
9	M12x80	80
A	Dowel sleeves for centralising
l  1) Starter to gearbox l  2) Also starter to gearbox l  3) Cover plate to gearbox

Tightening torques for engine/gearbox connection (1.4 ltr. TFSI engine):

Item	Bolt	Nm
1, 2, 3	M12×50	80
4 Bolt with stud M8	M12×55	80
5 Bolt with stud M8	M12x150	80
6, 9	M12×60	80
7, 8	M10x50	40
A	Dowel sleeves for centralising

–  Remove engine support -3300 A- and support -T10036-.

–  Bolt gearbox bracket to gearbox using new bolts -arrows 2-. Tightening torque → Chapter „Assembly mountings - exploded view“ –  Raise engine and gearbox and secure to gearbox mounting with new bolts -arrows 2-. Follow correct tightening sequence → Fig.. Tightening torque → Chapter „Assembly mountings - exploded view“

–  Bolt pendulum support onto gearbox first, and then secure to subframe -bolts 1 ... 3-. –  Use new bolts. Tightening torque → Chapter „Assembly mountings - exploded view“   Note Install engine/gearbox mountings stress-free → Rep. Gr.10.

–  Install starter → Electrical system; Rep. Gr.27. –  Secure earth wire -1- and wiring -2- and -3-.

Vehicles with start/stop system: –  Attach connector -arrow- for gearbox neutral position sender -G701-.

Continued for all vehicles: –  Secure bracket -3- together with electrical wiring -1- and -2-. –  Attach connector -4- for reversing light switch -F4-. –  Bolt drive shafts to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.. –  Install exhaust system and ensure stress-free alignment → Engine, mechanics; Rep. Gr.26..

–  Install clutch slave cylinder -arrows -. Tightening torque → Item –  Engage hose/pipe assembly -A- on bracket -B-.

–  Install cable support bracket on gearbox and tighten bolts -arrows-. Tightening torque → Item

–  Install gearbox selector lever -A-. Installation position → Item. –  Tighten new hexagon nut -arrow 4-. Tightening torque → Item –  Fit gate relay lever -B- in bearing on selector mechanism cover. –  When doing so, pivot gate relay lever so that slide block -C- engages in guide on gearbox selector lever. –  Secure gate relay lever with securing clip -arrow 3-. –  Apply a small amount of grease -G 000 450 02- to pins of gearbox selector lever -A- and gate relay lever -B-. –  Secure gear selector cable -arrow 1- and gate selector cable -arrow 2-. –  Adjust selector mechanism → Chapter. –  Install engine cover panel → Injection and ignition system; Rep. Gr.24. –  Fill up oil in gearbox and check oil level → Chapter. –  Install noise insulation. –  Install battery tray and battery → Electrical system; Rep. Gr.27. –  Install air cleaner housing → Injection and ignition system; Rep. Gr.24.