Removing gearbox

Make

Audi

Model

A1

Section

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

Power transmissionRemoving gearbox

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adapter -10 - 222 A /19-

t	Hook -2024 A/1- from lifting tackle -2024 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/31-

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

t  Engine support bracket, basic set -T40091- Procedure   Note Re-attach all cable ties at the same locations when re-installing.

Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  With ignition switched off, disconnect battery earth wire -1- and remove battery → Electrical system; Rep. gr.27.

–  Remove air cleaner housing → Injection and ignition system; Rep. gr.24.

–  Release retainers -arrows A- and lift out side panel for battery tray -arrow B-. –  Remove bolt -3- and nuts -1 and 2- and detach battery tray.

l  To avoid damage to the gate selector cable, the cable end-piece must be separated from the gate selector cable before removal. –  Pull locking mechanism forwards -arrow 1- onto stop and then turn to left -arrow 2- to lock. –  Push gate relay lever forwards in direction of -arrow 3-.

–  Remove securing clip -2-. –  Pull gear selector cable -1- off gearbox selector lever -4-. –  Remove nut -3- and detach gearbox selector lever.

–  Unscrew bolts -arrows-, remove cable support bracket -1- and place to one side together with cables.

–  Remove bolts -arrows-, detach clutch slave cylinder -1- and place to one side. Do not disconnect pipes.   Caution Risk of irreparable damage to clutch slave cylinder. Do not press clutch pedal after removing clutch slave cylinder.

–  Unplug electrical connector -2-. –  Detach cover for B+ wire -3-. –  Remove nut and move B+ wire clear. –  Remove bolt -1-.

–  Remove noise insulation -1- → General body repairs, exterior; Rep. gr.66. –  Remove wheel housing liner (front left) → General body repairs, exterior; Rep. gr.66.

Vehicles with start/stop system: –  Unplug electrical connector -3- from gearbox neutral position sender -G701-. Continued for all vehicles: –  Unplug electrical connector -2- at reversing light switch -F4-. –  Remove nut -1- and detach bracket for electrical wiring. Wiring remains connected. –  Remove bolt (bottom) and detach starter. –  Unbolt drive shafts (left and right) from flange shafts on gearbox → Running gear; Rep. gr.40.

–  Remove nuts -arrows- securing swivel joint (left-side). –  If fitted, unscrew nut on bracket for front left vehicle level sender -G78-. –  Disengage swivel joint (left-side) from wishbone.

–  Swivel suspension strut (left-side) outwards and support with hook -2024 A /1- as shown in illustration.   WARNING Risk of accident if parts of support are not properly secured. Secure locking pin and swivel joint with retaining clip -arrow- and nut -1-. –  Tie up drive shafts (left and right).   Note Make sure you do not damage surface coating on drive shaft. –  Remove flange shaft (right-side) → Chapter.

WARNING Risk of accident. The bolted connection -1- must not be slackened. –  Remove bolts -arrows- and detach pendulum support.

–  Loosen nuts -arrows- and move clamp towards rear.

–  Remove bolts -1- (accessible from above).

–  Set up support bracket -10 - 222 A- on wing mounting flanges, as shown in illustration. –  Engage hook of spindle -10 - 222 A /11- in engine lifting eye (left-side). –  Take up weight of engine with spindle; do not lift.

–  Remove bolts -arrows- from gearbox mounting.

–  Lower engine/gearbox assembly using spindle of support bracket -10 - 222 A- until distance -a- is obtained between gearbox support and gearbox mounting. l  Dimension -a- = 50 mm

–  Remove bolts -arrows- and detach gearbox support -A-.

To remove gearbox 02T, set up gearbox support -3282- with adjustment plate -3282/31-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate. –  Bolt on support elements -A-, as illustrated on adjustment plate. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. l  The arrow symbol -B- on the adjustment plate points in the direction of travel.

–  Align adjustment plate -3282/31- parallel to gearbox and lock safety support on gearbox.   Note -Arrow- can be disregarded.

–  Remove bolts -arrows- and detach cover plate -1-.

–  Remove remaining engine/gearbox securing bolts -1- and -3-. –  Press gearbox off dowel sleeves. –  Pull gearbox off engine.

–  Press engine forward slightly. –  Carefully lower 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. –  While lowering gearbox, change position of gearbox using spindles on gearbox support -3282-.

04 Transmission