Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Lifting tackle -2024 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/10-

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

t	Grease for clutch plate splines -G 000 100-

t	Copper grease -Z 381 351 TE-

Procedure   Note All cable ties which are released or cut open during removal must be fitted in the same position when installing.   WARNING t  Follow steps required when disconnecting battery → Rep. Gr.27. t  On vehicles with telematics: activate service mode of telematics control unit before disconnecting battery → Rep. Gr.91. –  Refer to coding on vehicles with encoded radio/radio navigation system; obtain coding if necessary.

–  With the ignition switched off, disconnect battery earth strap.

Vehicles with 4-cylinder turbo engine: –  Remove engine cover panel -arrows-.

–  Set up support bracket -10 - 222 A- with racks -10 - 222 A /1-. –  Take up some of the weight of the engine by means of the spindle.

Vehicles with 6-cylinder engine: –  Set up support bracket -10 - 222 A- with racks -10 - 222 A /1-. –  Take up some of the weight of the engine by means of the spindle. Continued for all vehicles:

–  Remove noise insulation -arrows-.

–  Remove heat shield for propshaft from cover for centre differential -arrows-.

Vehicles with 4-cylinder turbo engine: –  Release clamp -1- and remove front exhaust pipe -2- → Rep. Gr.26. Vehicles with 6-cylinder engine: –  Remove front exhaust system with catalytic converter → Rep. Gr.26. Continued for all vehicles: –  Unbolt propshaft -3- from gearbox and tie up to one side with wire (see next illustration) → Rep. Gr.39.

–  Unscrew speed nut -arrow- slightly and use it to secure propshaft with wire.

–  Unbolt bracket for noise insulation -arrow-.

–  Unscrew the three bottom engine/gearbox securing bolts -arrow-.

–  Detach heat shields -arrow 1- and -arrow 2- above right-hand drive shaft. –  If fitted, remove heat shield above drive shaft (right-side).

–  Remove drive shafts -1- from flange shafts and tie up to side.   Note Make sure you do not damage surface coating on drive shafts. –  Take up some of the weight of the gearbox with engine and gearbox jack -V.A.G 1383 A-.

–  First remove bolts -2- and then bolts -3- at tunnel cross member. –  Unscrew two nuts -4- and detach tunnel cross member. –  Lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Remove selector rod -arrow A-. –  Unscrew hexagon socket head bolt on push rod -arrow B-.

–  Unplug connector from speedometer sender -G22--arrow A-. –  Unplug connector from reversing light switch -F4- (multi-function sender) -arrow B-. –  Disconnect all other electrical connections and earth wires from gearbox and from engine/gearbox securing bolts.

–  If fitted, remove engine speed sender -G28- from left of gearbox -arrow- and move clear.

–  Unbolt starter from engine/gearbox and secure as necessary → Rep. Gr.27.   Note Starter cables do not have to be disconnected.

–  Set up gearbox support -3282- with adjustment plate -3282/10- to remove manual gearbox 012, and place gearbox support on engine and gearbox jack -V.A.G 1383 A-. A -  Support elements   Note t  Support elements -A- are shown in schematic form, arrow -B- points in the direction of travel. t  Adjustment plate -3282/10- can only be fitted in one correct position.

–  Place gearbox jack under vehicle; arrow symbol -B- on adjustment plate -3282/10- points to front of vehicle.

–  Align adjustment plate -3282/10- parallel to gearbox and lock safety support -arrow- on gearbox.

–  Remove remaining engine/gearbox securing bolts -arrow A- and -arrow B-. –  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 pipe/hose to slave cylinder is not damaged.

–  Remove slave cylinder -arrow- and secure with wire, do not open pipe/hose system.   Note Do not depress clutch pedal after removing slave cylinder. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. –  Lower gearbox completely.   Note When lowering gearbox ensure there is sufficient clearance from drive shafts. Before carrying out assembly work, secure gearbox to assembly stand with gearbox support -VW 353- and retaining plate -VW 309- → Chapter.

–  If the removed gearbox is being renewed, the gearbox support and gearbox mounting must be transferred to the replacement gearbox. Transporting the gearbox → Chapter