Audi Workshop Service and Repair Manuals

Removing gearbox   Note All cable ties which are released or cut open when removing the gearbox must be refitted in the same position when installing the gearbox. –  Remove engine cover panel. –  Obtain radio code on vehicles with coded radio. –  With the ignition switched off, disconnect battery earth strap.

–  If fitted, remove cover panel (front left) -arrows-.

–  If fitted, detach hose -1- for secondary air pump. –  Detach air intake hose at air mass meter -G70- (slacken hose clip -2-). –  Unplug electrical connector for air mass meter -G70--3-. –  Remove bolts -4- and -5- and detach air cleaner housing → Repair group 23 or → Repair group 24.

–  Remove battery and battery tray -arrows- → Rep. Gr.27.

–  Detach cable support bracket from gearbox, if necessary unclip pipe/hose assembly -arrows-.

Vehicles up to 09.98 –  Unplug connector from speedometer sender -G22--arrow 1-. –  Unplug connector from reversing light switch -F4--arrow 2-.

–  Detach damper weight -A- and gear selector cable -B- from gearbox selector lever. –  Unscrew gear selector cable and take off washer and square nut (self-locking). –  Pull gate selector cable off actuating arm/relay lever -C-, to do this lift lug in direction of -arrow-.

–  Remove slave cylinder -arrows-, move to one side and secure with wire. Do not disconnect pipes.   Caution Do not depress clutch pedal after removing slave cylinder.

–  Detach earth strap at upper engine/gearbox connecting bolt -1-. –  Remove upper engine/gearbox connecting bolts -1-. –  Unbolt cable retainer -3- at top of starter -arrow- and place to one side. –  Remove upper securing bolt on starter -2-. –  Remove all engine/gearbox securing bolts which are accessible from above.

Vehicles from 09.98   Caution Do not remove cable end-pieces from selector shaft lever or relay lever on vehicles up to 06.2001. Cable end-pieces must be renewed after removal. –  Remove securing clip -arrow- and pull off gate selector cable -A- with relay lever. –  Remove nut -arrow- and detach gear selector cable -B- with gearbox selector lever. –  Tie up gear selector cable with gearbox selector lever and gate selector cable with relay lever.

–  Unplug connector from speedometer sender -G22--arrow 1-. –  Unplug connector from reversing light switch -F4--arrow 2-.

–  Remove slave cylinder -arrows-, move to one side and secure with wire. Do not disconnect pipes.   Caution Do not depress clutch pedal after removing slave cylinder.

–  Remove cable retainer -arrow 1- on starter. –  Remove wiring and cable from starter. –  Detach earth strap at upper engine/gearbox connecting bolt. –  Then remove upper securing bolt -arrow 2- on starter. –  Remove upper engine/gearbox securing bolts. Continued for all vehicles –  If there are hoses and cable connections in area of engine lifting eyes for support bracket -10 - 222 A-, remove these now.

–  Assemble support bracket -10 - 222 A- together with racks -10 - 222 A /1-. –  Take up weight of engine/gearbox assembly with the spindles.

–  Unscrew bolts -arrows- and remove noise insulation completely. –  Remove starter → Rep. Gr.27. –  Remove retainer for power assisted steering pipe from gearbox.

–  If fitted, remove protective cover for right inner constant velocity joint from engine -arrows-.

–  Remove small cover plate -A- for flywheel behind right-hand flange shaft -arrows-. –  Disconnect drive shafts from flange shafts, turn steering to full left lock and tie up drive shafts as high as possible. Take care not to damage surface coating. –  Separate exhaust system behind catalytic converter → Rep. Gr.26.   Note t  On vehicles with TDI engines, the exhaust pipe bracket must be detached from the subframe. t  On vehicles with 5V turbo engines, the front exhaust pipe must be removed.

–  Unbolt pendulum support -arrows-.

–  Remove gearbox support from gearbox and gearbox bracket -arrows A-. –  Remove bolts -arrows B- at left mounting from gearbox mounting/gearbox bracket.   Note Do not damage power steering pipe when moving engine/gearbox assembly.

–  Lower engine/gearbox assembly via the two spindles until securing bolts for gearbox bracket -A- are accessible from left wheel housing. Separate gearbox bracket -A- from gearbox as follows: –  Using hot-air blower -V.A.G 1416-, heat self-locking bolts -arrows- slightly, otherwise the bolts -arrows- can shear off when they are loosened. –  Remove bolts -arrows- and release gearbox bracket -A- from gearbox.

–  Bolt support rail -VW 457/1- to both threaded holes for pendulum support securing holes on subframe. –  Spacers totalling 6 mm must be inserted between subframe and support rail -VW 457/1-. -A- 2 hexagon bolts M8 x 25 –  Fit engine support -3300 A- and secure -arrows-. –  Carefully press engine/gearbox unit forwards.   Note Do not damage power steering pipe. –  Assemble gearbox jack with gearbox support -3282-, adjustment plate -3282/8- for “02A” gearbox and support elements as follows: –  Place adjustment plate -3282/8- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate.

–  Bolt on support elements -A-, as illustrated on adjustment plate.

–  Place gearbox jack under vehicle; arrow symbol -B- ( → Anchor) on adjustment plate points to front of vehicle. –  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove bottom engine/gearbox securing bolts.

–  Push the gearbox off the dowel sleeves and swing carefully towards the subframe. –  Slightly lower gearbox and tilt to left via spindles of gearbox support -3282-.

–  Then lower gearbox carefully, guiding right-hand flange shaft -A- past flywheel as illustrated and left-hand flange shaft -B- past subframe. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-.   Note Do not damage power steering pipe when lowering gearbox. Transporting gearbox

–  Bolt gearbox lifting tackle -3336- to clutch housing.

–  Set support arm on sliding bracket by means of locking pin -arrow-. Number of holes visible = 5 –  Take up gearbox with workshop hoist and gearbox lifting tackle -3336-. –  Set down gearbox as required (for example in transport container).