Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 3.0 ltr. TDI engine Installation is carried out in reverse sequence; note the following: –  Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Always renew self-locking bolts and nuts. –  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 clutch release bearing for wear and make sure the plastic ring is securely attached; renew if necessary → Chapter. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  If fitted, place intermediate plate on dowel sleeves at engine flange. –  Before installing gearbox, tie electrical wiring and brackets off to one side so that they are not trapped between the engine and the gearbox. –  Place gearbox on gearbox jack.

–  Lightly lubricate surface where plunger and clutch release lever make contact -arrow B- using copper grease -Z 381 351 TE-. –  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for hose/pipe assembly. –  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-. –  Use new hexagon socket head bolt -2- to secure to gearbox.   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-.

–  Tighten bolt -arrow- to specified torque.   Caution After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The plunger of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Insert gearbox, making sure there is sufficient clearance to drive shafts.

–  Tighten engine/gearbox securing bolts -3- and -6 … 10-.

–  Fit gearbox selector lever -2- and tighten nut -1-. Tightening torque → Item

–  Bolt push rod -1- onto gearbox. Tightening torque → Item –  Secure connecting rod -2-. Tightening torque → Item

–  Secure tunnel cross member on gearbox mounting -4-. Tightening torque → Item –  Lift gearbox with engine and gearbox jack -V.A.G 1383 A-. Bolt tunnel cross member onto body as follows: –  Screw in bolts -2- and new bolts -3- hand-tight. –  Tighten bolts -3-. Tightening torques → Item –  Tighten bolts -2-. Tightening torques → Item –  Carefully lower engine and gearbox jack -V.A.G 1383 A- and move it aside. –  Bolt drive shafts -1- to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Install stop for torque reaction support and torque reaction support. –  Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and tighten nuts -arrows-.

–  Secure anti-roll bar to subframe at mountings -1- and -2- → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Install starter → Electrical system; Rep. Gr.27.

–  Attach connector -arrow- for reversing light switch -F4- on right side of gearbox.

–  Attach electrical connector -arrow- for engine speed sender -G28-.

–  It is important to clean the threaded holes for the propshaft bolts to remove any remaining locking fluid. The threads can be cleaned with a thread tap. –  Bolt propshaft onto gearbox -arrows- → Rear final drive 01R; Rep. Gr.39 or → Rear final drive 0AR; Rep. Gr.39 or → Rear final drive 0AR; Rep. Gr.39.

–  If fitted, install heat shield for propshaft -arrows-. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. Gr.26. –  Check gear oil level in gearbox → Chapter.

–  Install heat shield for drive shaft -arrow-.

–  Install noise insulation -1- for drive shaft (left-side) in wheel housing.

–  Install bracket for noise insulation. –  Install noise insulation (front and rear) with fasteners -1 … 3-. –  Remove support bracket -10-222 A-.

–  Tighten engine/gearbox securing bolts -4- and -5-. –  Install coolant expansion tank and air duct in engine compartment. –  Install engine cover panel. –  Check selector mechanism setting and adjust if necessary → Chapter. –  Follow steps required after connecting battery → Electrical system; Rep. Gr.27. 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%.

Engine/gearbox securing bolts

Item	Bolt	Nm
1, 2	M12x135	65 1)
3, 4, 5	M12x105	65
6, 7	M12x120	65
8, 9, 10	M10x80	45
A	Dowel sleeves for centralising
l  1) Property class 10.9.

Component	Nm
Clutch slave cylinder to gearbox	23 1)
Heat shield for propshaft to gearbox cover	25
Stop for torque reaction support to lock carrier	28
Bracket for anti-roll bar	25
Bracket for noise insulation to subframe	10
l  1) Use new bolts/nuts