Audi Workshop Service and Repair Manuals

Installation is carried out in the reverse order, when doing this note the following:

• ‒ 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. Do not grease guide sleeve.
• ‒ Check clutch release bearing for wear, renew if necessary.
• ‒ Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
• ‒ Before installing, use a tap to clean out locking fluid left in the threads of the clutch slave cylinder mounting on the gearbox and the selector lever/selector rod connection.
• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.
• ‒ Renew all self locking nuts.

• ‒ → Lift gearbox until clutch slave cylinder with bracket for hose/pipe can be installed (arrow).
• ‒ If gearbox has intermediate plate, fit between gearbox and engine onto engine dowel sleeves.
• ‒ Ensure that the intermediate plate is correctly positioned on engine.
• ‒ Install lower engine/gearbox securing bolts and bolts for starter, to do this insert the starter.

=> Electrical system; Repair Group 27; Removing and installing starter

• ‒ The threaded bores in the flange shaft of the manual gearbox for the propshaft must be cleaned of remaining locking fluid with a thread tap before assembling
• ‒ Replace front gaskets at propshaft and at drive shafts.
• ‒ Bolt on propshaft => Page39-83
• ‒ Check adjustment of shift mechanism, adjust if necessary => Page 34-24.

• ‒ Stress free alignment of exhaust system

=> 4-cylinder Engine (5-valve), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

=> 4-cylinder Engine (5-valve turbo), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

=> 4-cylinder Diesel Direct Injection Engine (TDI), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6-cylinder Engine (2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6-cylinder Engine (5-valve), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

• ‒ Check oil level in gearbox => Page 34-69.
• ‒ After connecting battery, enter anti theft code for radio.

=> Radio operating instructions

• ‒ Close windows fully using electric window switches.
• ‒ Then actuate all electric window switches again for at least one second in the "close" direction to activate the automatic open/close function.
• ‒ Set clock to correct time.

Tightening torques

→ Gearbox to engine 4-cylinder

5* = upper starter bolt

A: Centring sleeves

→ Gearbox/engine assemblymountings 4 cylinder

→ Gearbox to engine (6-cylinder)

5*= Also secure the bracket for coolant pipes

A: Centring sleeves

→ Gearbox/engine assembly mountings (6-cylinder)

    1)    Replace bolt