Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with V6 TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/12-

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

t  Counterhold tool -T10172- with adapter -T10172/5-

t  Used oil collection and extraction unit -V.A.G 1782-

t  Wing compensation plates -T40045-

Procedure   Caution Follow steps required when disconnecting battery → Rep. Gr.27. –  Detach rubber seal of plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- to front. –  With ignition switched off, disconnect earth wire at battery → Rep. Gr.27.

–  Remove engine cover panel -arrows-.

–  Pull off bonnet seal at both wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

–  Set up support bracket -10-222 A- with racks -10-222 A/1-. –  Take up some of the engine weight by tightening spindle of support bracket, but do not lift.

–  On vehicles fitted with auxiliary heater, remove screws -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Release fasteners -1 ... 3- and detach noise insulation panels (front -A- and rear -B-).

–  Detach bracket -arrow- for noise insulation.

–  Unscrew bolts -1 ... 4- and remove front cross piece, if fitted.

–  Unscrew nuts -1- at connection between starter catalytic converter and front exhaust pipe with catalytic converters.

–  Release clamps -1- and remove front exhaust pipe with catalytic converters -2-.

–  Unbolt heat shield for left-side drive shaft -arrows-. –  Remove drive shafts -1- (left and right) from gearbox flange shafts and tie up to side as far as possible.   Note Make sure you do not damage surface coating on drive shafts.

–  Unbolt heat shield for propshaft -arrows-.

–  Unbolt propshaft from gearbox. –  To do this, use counterhold tool -T10172- with adapter -T10172/5-

–  Use wire -arrow- to tie up propshaft -1- onto heat shield.

–  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 support gearbox.

–  First remove bolts -1- and then bolts -2- at rear cross member. –  Unscrew two nuts -3- and detach rear cross member.

–  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

–  Unscrew bottom engine/gearbox securing bolts -arrows-. –  Lower gearbox again.

–  Unplug electrical connector -arrow- for reversing light switch -F4- on gearbox (right-side). –  Move electrical wiring clear.

–  If fitted, unplug electrical connector -arrow- for speedometer sender -G22- on left of gearbox.

–  If fitted, unbolt head shield for engine speed sender -G28- from gearbox and remove bolt -arrow-. –  Remove engine speed sender -G28- and move clear.

–  Unscrew connecting rod -2- for selector rod. –  Detach push rod -1-; to do so, unscrew hexagon socket head bolt.

–  Unscrew nut -1- and detach selector shaft lever -2- from gearbox selector shaft.

–  Unbolt starter and secure to side of engine compartment if necessary → Rep. Gr.27.   Note Starter cables do not have to be disconnected. –  Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove gear oil pipes -arrows- and seal openings with plugs. –  Disconnect gear oil pipes at connection point in front of drive shaft (right-side) –  Unscrew bottom engine/gearbox securing bolts.

–  To remove manual gearbox 01E (four-wheel drive) set up gearbox support -3282- with adjustment plate -3282/12- and place on engine and gearbox jack -V.A.G 1383 A-. –  Fit support elements -A-.   Note

t  The positions of the support elements are shown on the adjustment plate -3282/12- in schematic form -A- (the arrow -B- points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Place engine and gearbox jack -1383 A- with gearbox support -3282- underneath gearbox and position adjustment plate so it is parallel with gearbox.

–  Secure support elements -arrow- to left and right side of gearbox.

–  Unscrew top engine/gearbox securing bolts -arrows-. –  Slacken bolt -1- (at rear of turbocharger) a few turns and pivot brace -2- to one side in direction of -arrow-. Then tighten bolt -1- again lightly. –  If fitted, move bracket -3- with wiring clear to the side and secure with wire. –  Press gearbox off dowel sleeves and lower carefully with engine and gearbox jack -V.A.G 1383 A- just far enough to gain access to the clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic pipe/hose to slave cylinder is not damaged.

–  Remove clutch slave cylinder -arrow- and tie up with wire. Do not disconnect hoses/pipes.   Caution t  Do not depress clutch pedal after removing clutch slave cylinder. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely with engine and gearbox jack -V.A.G 1383 A-.   Note t  Make sure that all wiring has been detached from top of gearbox. t  When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being renewed, the gearbox mounting -1- must be transferred to the replacement gearbox -bolts 2-.