Installing gearbox

Make

Audi

Model

A1

Section

5-speed manual gearbox 02T › Gearbox mechanics,operation, construction,diff. › Installing gearbox

Power transmissionInstalling gearbox

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 -B- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.   Caution If the dowel sleeves -arrows B- 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 -arrow A- and fitted on the dowel sleeves -arrows B-. –  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 shaft (right-side) when installing a new gearbox or exchange gearbox. –  Check oil seal for flange shaft (right-side) for leakage and renew if necessary → 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 -3282/31- 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 the 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. –  Bolt gearbox support to gearbox mounting → Chapter.   WARNING Risk of accident. 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 shaft (right-side) → Chapter. –  Secure drive shafts to gearbox flange shafts → Running gear; Rep. gr.40. –  Install clutch slave cylinder → Chapter.

–  Gearbox for vehicles with start/stop system: plug connector -arrow- into gearbox neutral position sender -G701-. –  Install starter → Electrical system; Rep. gr.27. –  Adjust selector mechanism → Chapter. –  Check oil level in gearbox and top up with gear oil if necessary → Chapter. –  Install battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Injection and ignition system; Rep. gr.24.

Tightening torques

Item	Bolt	Nm
1	M12x65	80
2 1)	M12x140	80
3	M12x80	80
4	M10x50	40
A	Dowel sleeves for centralising
l  1) Also secures starter.

04 Transmission