Audi Workshop Service and Repair Manuals

Install in reverse order, paying attention to the following:

Notes:

• ◆ Replace self-locking nuts and bolts when performing assembly work.
• ◆ Replace bolts tightened to torque as well as sealing rings and gaskets.
• ◆ Secure all hose connections with standard hose clamps.

=> Parts List

• ◆ All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.
• ◆ Before installing gearbox, tie wiring to one side so that it cannot be trapped between engine and gearbox.
• ◆ Check whether dowel sleeves for centring engine/gearbox have been fitted in engine flange and insert if necessary .
• ◆ If gearbox is replaced, transfer gearbox supports with gearbox mounting. Tightening torques => Page 34-142.

• ◆ → 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.
• ◆ Tightening torques only apply to slightly greased, oiled, phosphated or blackened nuts and bolts.
• ◆ Additional lubricants, such as engine or gear oil are permitted, however not lubricants which contain graphite.
• ◆ Use is never to be made of degreased parts.
• ◆ Tolerance for tightening torques ±15%

• ‒ → Before installing slave cylinder in gearbox housing, area -a- of boot must be coated with lithium grease G 052 150 A2.
• ‒ On vehicles with gear oil cooling, blow out oil pipes and cooler with compressed air on completion of gearbox repairs/replacement.
• ‒ Prior to assembly, always use thread tap to remove remnants of locking fluid from tapped holes in flange shaft of manual gearbox for propshaft.

• ‒ Clean input shaft splines and - in the case of used clutch plates - hub splines, remove corrosion and apply extremely thin layer of grease G 000 100 to splines. Do not grease guide sleeve.
• ‒ Check clutch release bearing for wear and replace if necessary.
• ‒ → If plastic ring of release bearing is loose, bond it back onto bearing race with adhesive AMV 195 KD1 01.
• ‒ Three square lugs -arrows- of the plastic ring engage in the recesses of the bearing race.

• ‒ Release bearing must be replaced in the event of scoring deeper than 0.5 mm.
• Apply thin coat of copper grease, e.g. Z 381 351 TE, to contact surface for plunger at clutch release lever.
• → Use adhesive tape -arrows- to attach selector rod -1- and push rod -2- to underside of vehicle (propshaft tunnel).
• Before installing gearbox, tie wiring to one side so that it cannot be trapped between engine and gearbox.

• ‒ Position intermediate plate on dowel sleeves.
• ‒ → Insert lower starter bolt -arrow- in gearbox housing. It may not be possible to fit bolt with gearbox in position.

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 raise gearbox. In doing so, pay attention to clearance with respect to drive shafts, propshaft and subframe.

• ‒ → Raise gearbox such that clutch slave cylinder can be installed with holder for hose/pipe assembly (arrow).

• ‒ Insert gearbox.

• ‒ → Tighten upper engine/gearbox connecting bolts -arrows- to torque
  => Table, Page 34-140.
• ‒ Detach gearbox lifter from gearbox after bolting gearbox to engine.

• ‒ → Re-attach all cable ties, clips and heat insulation mats -arrows- at original locations.

• ‒ → Press selector lever on gearbox -2- onto gearbox selector shaft.
• ‒ Tighten nut -1- to 23 Nm.

Note:

→ Cover for selector shaft is provided with an additional tapped hole

-arrow A- as attachment point for newer connecting rod versions.

Distinguishing feature => Page 34-35

• ‒ → Screw (40 Nm) push rod -1- to gearbox with washers if applicable.
• ‒ Screw (23 Nm) connecting rod of selector rod -2- to right side of gearbox.
• ‒ Attach reversing light connector.
• ‒ Attach connector of speedometer sender.

• ‒ → Attach engine speed sender -G28 to gearbox housing -arrow-.
• ‒ Raise gearbox with gearbox lifter V.A.G 1383A.

Note:

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

• ‒ Screw in bolts for engine/gearbox attachment at bottom as well as for starter; to do so, insert starter.
• ‒ Fit and secure starter.

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

• ‒ → Screw right and left gearbox support complete with bonded rubber bush to gearbox and subframe (bolts -1- and -2-).

• ‒ → Secure subframe with bolts -2- and -3-.

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

• ‒ Install subframe and, if applicable, cross member at subframe.

=> Running Gear, Front-wheel Drive and Four-wheel Drive; Repair Group 40; Removing and installing subframe; Removing and installing lower cross member

• ‒ → Attach drive shafts -1- to flange shafts.

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

• ‒ Attach shield/drive shaft on right and left -arrows-. Third bolt is not shown.

• ‒ Install oil pipes => Page 34-145.
• ‒ Replace seal at front of propshaft => Page 39-85.
• ‒ Bolt on propshaft => Page39-91.
• ‒ → Attach shield for propshaft -arrows-.

• ‒ → Fit Lambda probe -arrow-, assemble exhaust system and perform stress-free alignment.

=> Engine, Mechanics; Repair Group 26; Removing and installing exhaust system components

• ‒ Check and if necessary adjust setting of selector rod and push rod => Page 34-16.
• ‒ Check gear oil level in manual gearbox => Page 34-143.
• ‒ Heed appropriate instructions for battery connection.

=> Electrical System; Repair Group 27

• ‒ After connecting battery, enter radio anti-theft code.

=> Radio operating instructions

• ‒ Use electric window lifters to completely close door windows.
• ‒ Then actuate all window lifter switches again for at least 1 second in "close" position to activate automatic one-touch function.
• ‒ Set clock to correct time.

Tightening torques

Note:

Depending on version, bolts of differing length may be used for a given item.

Dowel sleeves -A- for centring

    1)    Bolt not fitted on all versions

    1)    Always replace bolts

→ Right and left gearbox support to gearbox

→ Right and left gearbox mounting to gearbox support/subframe

    1)    Bolt -G- is screwed directly into gearbox mounting -H-. Items -B- and -C- not applicable.