Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with V6 TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/12-

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

t  Wing compensation plates -T40045-

Procedure   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27. –  Disconnect earth wire at battery. –  Pull off engine cover panel -arrows-.

–  Detach rubber seal from edges of wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

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

–  On vehicles fitted with auxiliary heater, remove screws -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Release fasteners -1 ... 3- and detach noise insulation panels (front -A- and rear -B-).

–  Detach bracket -arrow- for noise insulation.

–  Remove nuts -arrows-.

–  Remove bolt -1-.

–  If fitted, remove tunnel brace -1--arrows-. –  Release clamp -2- and remove front exhaust pipe with catalytic converter -3-.

–  Unbolt heat shield for left-side drive shaft -arrows-. –  Unbolt both drive shafts from flange shafts (left-side drive shaft -1- shown in illustration). –  Tie up the drive shafts.   Note Make sure you do not damage surface coating on drive shafts.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -1- between lifting column and gearbox). –  Take up some of the weight of the gearbox with engine and gearbox jack -V.A.G 1383 A-.

–  First remove bolts -1- and then bolts -2- at tunnel cross member. –  Unscrew two nuts -3- and detach tunnel cross member. –  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

–  Unscrew the 3 bottom engine/gearbox securing bolts -arrows-. –  Lower gearbox again.

–  Unplug electrical connector -arrow- for reversing light switch -F4- on right side of gearbox and move electrical wire clear.

–  If fitted, unplug electrical connector -arrow- for speedometer sender -G22- on left of gearbox.

–  If fitted, remove engine speed sender -G28- from left side of gearbox -arrow- and lay aside.

–  Unbolt connecting rod -2- for selector rod on right-hand side of gearbox. –  Unscrew push rod -1- by using an 8 mm hexagon key when unscrewing bolt.

–  Unscrew nut -1- and detach selector shaft lever -2- from selector shaft.

–  Unbolt starter and secure to side of engine compartment if necessary → Rep. Gr.27.   Note Starter cables do not have to be disconnected. –  Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts. –  Unscrew bottom engine/gearbox securing bolts.

–  To remove manual gearbox 01E (front-wheel drive) set up gearbox support -3282- with adjustment plate -3282/12- and place on engine and gearbox jack -V.A.G 1383 A-. –  Fit support elements -A-.   Note

t  The positions of the support elements are shown on the adjustment plate -3282/12- in schematic form -A- (the arrow -B- points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Place engine and gearbox jack -1383 A- with gearbox support -3282- underneath gearbox and position adjustment plate so it is parallel with gearbox.

–  Secure support elements -arrow- to left and right side of gearbox.

–  Unscrew top engine/gearbox securing bolts -arrows-. –  Slacken bolt -1- (at rear of turbocharger) a few turns and pivot brace -2- to one side in direction of arrow. Then tighten bolt -1- again lightly. –  If fitted, move bracket -3- with wiring clear to the side and secure with wire. –  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 hydraulic pipe/hose to slave cylinder is not damaged.

–  Remove slave cylinder -arrow- and secure with wire, do not open pipe/hose system. –  Lower gearbox all the way.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being renewed, the gearbox mounting -arrows- must be transferred to the replacement gearbox. Installing gearbox → Chapter.