Audi Workshop Service and Repair Manuals

Installing gearbox Installation is carried out in reverse sequence; note the following:   Note t  Renew self-locking nuts and bolts. t  Always renew seals/gaskets, oil seals and O-rings. –  In vehicles with gearbox oil cooling blow out gear oil pipes and gear oil cooler with compressed air after repairing or exchanging gearbox. –  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. Do not grease guide sleeve. l  It should be possible to push the clutch plate back and forth slightly on the input shaft. –  Check whether dowel sleeves for aligning gearbox with engine are in the engine flange. Insert if necessary → Anchor. –  Check clutch release bearing for wear and renew if necessary. –  Checking and servicing release bearing with glued plastic ring → Fig.. –  Checking release bearing with mechanically attached plastic ring → Fig.. –  Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  If fitted, place intermediate plate on dowel sleeves at engine flange. –  Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between engine and gearbox.

Vehicles with V6 TDI engine: –  Before installing gearbox, check that brace -B- is still moved to one side -direction of arrow-.

All models: –  Before inserting slave cylinder in gearbox housing, lubricate area -a- of sleeve with lithium grease -G 052 150 A2-.

–  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for hose/pipe assembly. –  Using copper grease -Z 381 351 TE-, lightly lubricate surface where plunger makes contact with clutch release lever -arrow B-. –  Guide slave cylinder -1- into opening in gearbox housing keeping it as straight as possible (without tilting plunger -arrow A-) and insert in recess -arrow B- on clutch release lever -3-.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-. –  Secure slave cylinder with new bolt -2-. –  When aligning the gearbox with the engine, turn crankshaft back and forth slightly to make it easier to insert the gearbox input shaft splines into the clutch plate.   Caution t  After installing the slave cylinder press the clutch pedal carefully. t  If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. t  The plunger of the slave cylinder is likely to have been guided past the clutch release lever. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. t  For comparison: normal pedal force is approx. 115 N. –  Install starter and tighten left and right engine/gearbox connecting bolts. –  Install connecting rod and push rod of selector mechanism.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -arrow- between lifting column and gearbox) and lift gearbox slightly.

–  Tighten the bottom engine/gearbox securing bolts -arrow-. –  Lower gearbox slightly again.

–  Secure rear cross member onto gearbox mounting -3-. –  Raise gearbox using engine and gearbox jack -V.A.G 1383 A- and secure rear cross member to body using bolts -1- and -2- → Rep. Gr.40. –  Bolt drive shafts to gearbox flanges → Rep. Gr.40. –  If fitted, install gear oil pipes → Chapter. –  Secure propshaft to gearbox → Rear final drive 01R; Rep. Gr.39. –  Install exhaust system and align it so it is stress-free → Rep. Gr.26. –  Check selector mechanism for correct adjustment, and re-adjust if necessary → Chapter. –  If fitted, install front cross piece → Rep. Gr.66. –  Follow the steps required after connecting the battery → Rep. Gr.27. –  Check oil level in manual gearbox → Chapter. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques ±15 %.

Securing gearbox to engine - vehicles with 4-cyl. petrol engine

Item	Bolt	Nm
1	M12 x 67	65
2	M12 x 110 1)	65
3	M12 x 90	65
4	M10 x 50 2)	45
5	M10 x 45	45
6	M12 x 110 3)	65
A	Dowel sleeves for centralising
l  1) With bracket for wiring l  2) Special bolt with nut l  3) With nut

Securing gearbox to engine - vehicles with 4-cyl. TDI engine:

Item	Bolt	Nm
1	M12 x 75	65
2	M12 x 110 1)	65
3	M12 x 90	65
4	M10 x 50 2)	45
5	M10 x 45	45
6	M12 x 110 3)	65
A	Dowel sleeves for centralising
l  1) With bracket for wiring l  2) Special bolt with nut l  3) With nut

Securing gearbox to engine - vehicles with V6 petrol engine

Item	Bolt	Nm
1, 10, 11	M10x60	45
2	M12x130	65
3	M10x150	45
4	M12x80	65
5, 6, 8	M12x80	65
7	M12x105	65
9	M10x59	45
A	Dowel sleeves for centralising
l  1) Renew bolts.

Securing gearbox to engine - vehicles with V6 TDI engine

Item	Bolt	Nm
1, 3	M12x80	65
2	M12x90	65
4	M10x50	45
5	M10x45	45
6, 7	M12x110	65
8	M12x67	65
A	Dowel sleeves for centralising
l  1) Renew bolts.

Component	Nm
Clutch slave cylinder to gearbox	25 1)
Push rod to gearbox	40
Selector shaft lever to gearbox	23
Connecting rod for selector rod to gearbox	23
Engine speed sender -G28- to gearbox	10
Gearbox mounting with bracket to gearbox	23
Heat shield for drive shaft to gearbox	23
Heat shield for propshaft to Torsen differential cover	25
Bracket for noise insulation to subframe	10
Air duct to throttle valve housing	10
l  1) Renew bolt