Audi Workshop Service and Repair Manuals

Installing gearbox Installation is carried out in reverse sequence; note the following:   Note t  Renew bolts which are tightened by turning through a specified angle. t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Re-attach all cable ties at the same locations when re-installing. t  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 for clutch plate splines -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.   Note If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

–  Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves -arrows-. –  Check clutch release bearing for wear and renew if necessary. –  Lubricate surface which contacts ball-head pin with MoS2 grease. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. l  The arrow symbol on the adjustment plate points in the direction of travel. –  Remove flange shafts when installing a new gearbox or exchange gearbox. –  Check oil seals for flange shafts and renew if necessary: left-side → Chapter, right-side → Chapter.

–  Carefully lift gearbox using engine and gearbox jack -V.A.G 1383 A- and ensure sufficient clearance between sleeve -1- and clutch pressure plate -arrow- to prevent damage. –  Bring gearbox into position. –  Install bottom engine/gearbox securing bolts. –  Detach gearbox support -3282- with adjustment plate -3282/39- from gearbox after bolting gearbox and engine together.

–  Install gearbox support -A- → Chapter. –  Install top engine/gearbox securing bolts. –  Raise engine/gearbox assembly via spindle of support bracket -10 - 222 A-.

–  Align engine/gearbox assembly in installation position. To do so, raise engine/gearbox until gearbox support makes full contact with gearbox mounting.   Caution The threads in the gearbox support can be damaged if the bolts are not inserted straight. Before fitting the bolts -arrows-, the gearbox support and the support arm of the gearbox mounting must be aligned absolutely parallel. If necessary, push the gearbox up at the rear with a trolley jack. –  Bolt gearbox support to gearbox mounting → Chapter.   WARNING Do not remove support bracket -10 - 222 A- until all bolts securing the left-hand engine/gearbox mounting have been tightened to the specified torque. –  Install pendulum support → Chapter. –  Install flange shafts: left-side → Chapter, right-side → Chapter. –  Secure drive shafts to gearbox flange shafts → Running gear; Rep. gr.40. –  If removed earlier, bolt on heat shield for drive shaft (right-side). –  Install clutch slave cylinder → Chapter. –  Install radiator cowl → Engine, mechanics; Rep. gr.19. –  Install starter → Electrical system; Rep. gr.27.

–  Gearbox for vehicles with start/stop system: plug connector -arrow- into gearbox neutral position sender -G701-.

–  Plug connector -3- onto reversing light switch -F4-. –  Assemble selector mechanism → Chapter. –  Adjust selector mechanism → Chapter. –  Check oil level in gearbox and top up with gear oil if necessary → Chapter. –  Install air cleaner housing → Injection and glow plug system; Rep. gr.23.

Tightening torques

Item	Bolt	Nm
1	M12x55	80
2 1)	M12x150	80
3	M10x50	40
4	M12x60	80
A	Dowel sleeves for centralising
l  1) Also secures starter.

Note -Item 5- can be disregarded.