Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Gearbox mount 3282
• ◆ Adjustment plate 3282/12
• ◆ Engine/gearbox lifter V.A.G 1383 A

Special tools, testers and other items required

• ◆ Drip tray V.A.G 1306

Note:

All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

• ‒ Heed (if necessary obtain) code for vehicles with encoded radio/radio navigation system (RNS).
• ‒ → Remove cover over battery -arrows-.

• ‒ → Disconnect earth strap -arrow- at battery with ignition switched off.

• ‒ → Detach noise insulation -arrows-.

• ‒ → Unscrew holder for noise insulation -arrow-.

• ‒ → Detach heat shield over left and right drive shaft from gearbox
  -arrows-. Third bolt is not shown.
• ‒ Unscrew drive shafts -1- on left and right from gearbox flange.

=> Running Gear, Front-wheel Drive and Four-wheel Drive; Repair Group 40; Removing and installing drive shaft

Note:

Take care not to damage surface protection of drive shafts.

• ‒ → If fitted, screw out Lambda probe on left -arrow- and lay it aside.

• ‒ → Unfasten clamping sleeves -arrows- and slide to rear.

• ‒ → Unscrew heat shield for propshaft from cover for Torsen differential -arrows-.

• ‒ → Unscrew propshaft -1- at gearbox and set down on heat shield -2-.
• ‒ Use wire -arrow- to attach propshaft to holder -3- of fuel pipes.

• ‒ → Slacken off bolts -arrows- and detach cross member -A-.

• ‒ → Unscrew both exhaust system brackets. To do so, screw out bolts -1- and -2-.

• ‒ → Use gearbox lifter V.A.G 1383 A to raise gearbox slightly.

A - Wooden block

• ‒ → Screw out bolts -1- and -2- on right and left side.

Note:

Bolts -3- and -4- are not to be screwed out, as otherwise wheel alignment would have to be performed.

• ‒ → Lower subframe at rear and insert spacer, e.g. wooden wedge, in gap.

• ◆ Dimension -a- max. 50 mm

• ‒ → Screw out bolts -2- on right and left side and use gearbox lifter V.A.G 1383 A to raise gearbox slightly again.
• ‒ Screw out bolts -1- and take out right and left gearbox supports complete with bonded rubber bush.

• ‒ → Raise gearbox further.

Note:

Take care not to damage selector rods on further raising gearbox.

• ‒ → Screw out the 2/3 lower engine/gearbox connecting bolts -arrows-.

Note:

To permit tightening of the two bolts -arrows- with a torque wrench following gearbox installation, the two hexagon socket-head bolts M10x60 must be replaced with new hexagon bolts M10x55, part no. N 104 684 01.

• ‒ Slowly lower gearbox again and move gearbox lifter aside.

• ‒ → Remove engine speed sender -G28 on left of gearbox -arrow- and lay aside.

• ‒ → Unplug connector -arrow-at speedometer sender -G22 on left of gearbox.

Important note on subsequent operations:

→ When removing shift mechanism (up to approx. 11.00), never detach ball end -arrow A- of connecting rod -2- from selector rod -1-.

Detaching would destroy ball end.

• ‒ → Unscrew nut -1- and pull lever -2- of selector rod off gearbox selector shaft.

Version with push rod on side:

• ‒ → Screw out hexagon socket-head bolt of push rod -1-.

Version with push rod at top:

• ‒ → Screw out 8 mm hexagon socket-head bolt of push rod -1-.

Note:

Packing plates may have been fitted between gearbox and push rod. If this is the case, they must be inserted again on assembly.

All models:

• ‒ Unscrew connecting rod -2- on right side of gearbox.
• ‒ Unplug connector -3- for reversing light switch on right of gearbox and lay bare wire.

• ‒ Place drip tray V.A.G 1306 in position.
• ‒ → Detach oil pipes for gear oil cooling at separation points -arrows- in front of right drive shaft.

• ‒ → Unscrew oil pipes at gearbox -arrows-. Seal holes with plugs.

Notes:

• ◆ Starter cables do not have to be disconnected.
• ◆ Bolt -2- may make contact with drive shaft and cannot be pulled out entirely.

• ‒ → Screw out starter bolts -1- and -2- or pull them out as far as possible. Secure starter to side of engine compartment if necessary.

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

• ‒ → Unfasten all cable ties/clips for attaching wiring harness to gearbox -arrows- and lay bare wiring harness over gearbox.

• ‒ → Screw out engine/gearbox connecting bolts at top -arrows-.

Note:

Leave connecting bolt -A- screwed in to hold in position.

Notes:

• ◆ → Mounting elements -A- are illustrated symbolically, arrow -B- faces in direction of travel.
• ◆ Adjustment plate 3282/12 only fits in one position.
• ◆ Elongated holes in adjustment plate 3282/12 can accommodate different gearbox housing and gearbox cover versions.

• ‒ → Position gearbox mount 3282 on gearbox lifter V.A.G 1383 A.
• ‒ Align arms of gearbox mount to coincide with holes in adjustment plate.
• ‒ Screw in mounting elements -A- as shown on adjustment plate.

• ‒ → Position gearbox lifter V.A.G 1383 A with gearbox mount 3282 beneath gearbox and attach as shown to left ...

• ‒ → ... and right side of gearbox.

• ‒ Screw out remaining engine/gearbox connecting bolts.
• ‒ → Press gearbox off dowel sleeves and move gearbox away from engine and parallel with it until there is a small gap -arrows- between gearbox and clutch.

• ‒ → Lower gearbox slightly with gearbox lifter V.A.G 1383 A until bolt
  -arrow- at slave cylinder is just accessible.
• ‒ Screw out bolt -arrow- and pull out clutch slave cylinder to rear.
  Do not open piping system.

Note:

Do not press clutch pedal after removing slave cylinder.

Note:

Take care not to over-deflectdecoupling element (flexible pipe connection) at front exhaust pipe. Catalytic converter must notbe offset by more than 10 °with respect to front exhaust pipe as otherwise decoupling element would be damaged.

• ‒ → Press the two catalytic converters apart (max. 10°) and completely lower gearbox.

Note:

On lowering, ensure clearance with respect to drive shafts.

Gearbox transportation

• ‒ → Insert transportation device T40013 in lifting eye of gearbox and secure.
• ‒ Engage hook of workshop crane in 4th mount -arrow- of transportation device.
• ‒ Support gearbox with workshop crane and transportation device T40013.