Audi Workshop Service and Repair Manuals

Installing gearbox Procedure   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. Tightening torques for installing gearbox → Anchor

–  Check whether there are dowel sleeves -A- and -B- for centring the engine and gearbox in the cylinder block; fit any missing dowel sleeves. –  If fitted, ensure that the intermediate plate is correctly positioned on engine. –  Clean the input shaft splines and hub splines on used clutch plates, remove corrosion and apply an extremely thin layer of clutch plate grease -G 000 100- to the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the input shaft. It is important to remove excess grease.

–  Raise gearbox carefully using gearbox support -3282-. –  Align gearbox with engine and install.

–  Screw in the bolts -1- and -2- connecting the engine to the gearbox at the bottom and tighten; then screw in and tighten the bolts at the top → Anchor. –  Install gearbox bracket → Fig.. –  Align the engine/gearbox assembly in installation position. To do so, tighten both spindles at the support bar -10 - 222 A-. –  Install gearbox mounting → Fig..   Note Ensure stress-free installation of the engine/gearbox assembly.   WARNING Risk of accident. Do not detach the support bar -10 - 222 A- until the gearbox bracket bolts have been tightened to torque. –  Detach the support bar. –  Install starter → Rep. gr.27. –  Install the reversing light switch -F4- → Chapter. –  Vehicles with power-assisted steering: install hydraulic lines → Rep. gr.48. –  Install drive shafts → Rep. gr.40. –  Install heat shield for drive shaft (right-side) → Fig.. –  Install pendulum support → Rep. gr.10. –  Install the starter catalytic converter → Rep. gr.26. –  Fit the gear actuator → Chapter.   Note

t  With a new gearbox, always take out the spring -arrow- between the release lever and gearbox as otherwise proper operation of the clutch slave cylinder is not guaranteed. t  The spring acts as transportation safeguard for the release bearing. –  Fit the holder for the clutch slave cylinder → Chapter. –  Install clutch slave cylinder → Chapter. –  Check gear oil level and top up as required → Chapter. –  Install noise insulation → Rep. gr.50. –  Install hydraulic control unit → Chapter. –  Observe correct procedure after connecting battery → Rep. gr.27.   Caution Overvoltage can cause irreparable damage to control units. Do not use charger for boost starting, –  Check the fluid level in the reservoir for the clutch mechanism and selector mechanism and replenish the fluid → Booklet809. –  Adjust the clutch → Chapter. –  Perform basic setting in the „vehicle self-diagnosis“ routine → Rep. gr.01. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques is ± 15 %.

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65

Heat shield for drive shaft (right-side) - tightening torque –  Tighten the bolts for the drive shaft heat shield -arrow- to 23 Nm.

Tightening torque for gearbox bracket –  Tighten bolts -A- for gearbox bracket -B- to 50 Nm and turn a further 90°.

Tightening torque for gearbox mounting –  Tighten the gearbox mounting bolts -arrows- to 40 Nm and give a further 90° turn.

Gearbox to engine

Item	Bolt	Nm
1, 2	M12x60	80
3	M12x80	80
4 1)	M10x50	45
5 2)	M12x180	80
A, B	Dowel sleeves for centralising
l  1) Tighten from engine end. l  2) Also secures starter.