Audi Workshop Service and Repair Manuals

Installing gearbox Installation of gearbox is carried out in reverse order of removal. When installing gearbox, ensure that engine/gearbox mountings are free of stress → Rep. Gr.10.   Note

t  Before installing gearbox, press clutch release lever towards gearbox housing and secure with assembly bolt or M8 x 35 bolt. Remove after gearbox has been installed. The hole will then be sealed by the 3rd securing bolt for the cable support bracket.

t  When installing a new gearbox, the speedometer sender -G22- (illustration), gearbox selector lever, gate relay lever and bracket for clutch pipe/hose assembly must be transferred to the new unit. t  Clean splines of input shaft and apply a thin coat of grease for clutch plate splines -G 000 100-. t  It should be possible to push the clutch plate back and forth slightly on the input shaft. t  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. t  When renewing gearbox, ensure that intermediate plate is correctly positioned. –  Align adjustment plate -3282/8- and gearbox parallel with one another and lock safety support on gearbox.

–  Place gearbox jack under vehicle; arrow symbol -B- on adjustment plate -3282/8- points to front of vehicle. –  Incline gearbox to left via spindles of gearbox support -3282-. –  Bring gearbox into position. –  Install bottom engine/gearbox securing bolts.

–  Fit gearbox bracket -A- with new bolts -arrows-. –  Install upper engine/gearbox securing bolts. –  Lift engine/gearbox assembly slightly via the spindles of support bracket -10 - 222 A-. –  Align engine/gearbox in installation position.

–  Install new hexagon bolts -arrows B- for assembly mounting (left-side) in gearbox mounting.   WARNING Do not detach the support bracket -10 - 222 A- until the bolts securing the gearbox bracket (left-side) have been tightened to torque.

–  Install pendulum support -arrows-. t  Use new bolts.

–  Attach connector to speedometer sender -G22- (-arrow-).

–  If it was removed, install small cover plate -A- behind drive flange (right-side) -arrows-. –  Secure coupling rod to anti-roll bar and suspension link to wheel bearing housing → Rep. Gr.40. –  Attach drive shafts to gearbox. –  Install protective cover for inner constant velocity joint (right-side) on engine, if fitted. –  Install starter → Rep. Gr.27.

–  Connect earth wire -B- at bottom securing bolt on starter. –  Plug in connector for reversing light switch -F4- (-2-) and connector -3- on starter. –  Connect wire -4- at solenoid switch, terminal 30.

–  Install clutch slave cylinder and attach pipe/hose assembly in bracket on gearbox.

–  Bolt cable support bracket to gearbox -arrows-.

–  Fit gearbox selector lever and secure with new nut -arrow 2-. –  Slide in gate relay lever and secure with clip -arrow 1-. –  Adjust selector mechanism → Chapter.

–  Install cross brace -A-. –  Install engine cover panel. –  Connect the battery. t  When the battery is reconnected, please remember to check and activate the vehicle equipment (radio, clock, convenience electrical systems etc.). –  Check gear oil level in gearbox → Chapter.

–  Install noise insulation below engine/gearbox, if fitted. Tightening torques

Gearbox to engine

Item	Bolt	Qty.	Nm
1 1)	M 12 x 55	1	80
2	M 12 x 55	2	80
3	M 10 x 50	2	40
4 1)2)	M 12 x 150	2	80
5 3)	M 6 x 12	1	10
1) Bolt with stud M8 2) Also secures starter to gearbox 3) Small flywheel cover plate

Items A + B - dowel sleeves

Gearbox bracket -A- to gearbox –  Renew bolts.

Bolts -arrows-

50 Nm + 90°

Gearbox to body –  Renew bolts.

Bolts -arrows-

40 Nm + 90°

Rear gearbox mounting –  Renew bolts.

Bolts -A-	50 Nm
Bolt -B-	40 Nm + 90°

–  Install cross brace -A-.

Nut -1-	20 Nm
Bolt -2-	20 Nm

Drive shaft to flange shaft M10		→ Rep. Gr.40
Selector cable support bracket to gearbox		23 Nm
Gearbox selector lever to gearbox		23 Nm
Clutch slave cylinder to gearbox		23 Nm
Bracket for clutch pipe/hose assembly to gearbox		25 Nm
Drive shaft protective cover to engine		35 Nm
Wheel bolts to wheel hub		→ Rep. Gr.44