Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 1.6 ltr. TDI engine Installation is carried out in reverse sequence; note the following: Please note the information in the table below - „Checking gear oil and filling up with gear oil“

„Checking gear oil level and filling up with gear oil“
		»No«	»Yes«	»Yes«
Gearbox	Genuine part	X
	No oil escaping	X
	Was completely dismantled		X Before installing → Item Oil capacity → Chapter
	Was partially dismantled l  (gearbox housing and clutch housing were not separated)			X After installing → Chapter

Note t  The special tools required are listed in the procedure for → Chapter „Removing gearbox - vehicles with 1.6 ltr. TDI engine“. t  Renew self-locking nuts and bolts when performing assembly work. t  Renew oil seals and gaskets, and bolts which are tightened by turning through a specified angle. 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 -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. If the dowel sleeves 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 and fitted on the dowel sleeves -arrows-. –  Check clutch release bearing for wear and renew if necessary. –  Lubricate surface which contacts ball-head pin with grease for clutch plate splines -G 000 100-.

–  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 -3282/39-. –  Screw support elements-A- and pin -3282/29- (-C-) into adjustment plate, as illustrated.

–  Align adjustment plate -3282/39- parallel to gearbox and lock safety support on gearbox. –  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox. –  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) -arrow- when installing a new gearbox or exchange gearbox. –  Check flange shaft oil seals for leaks and renew if necessary → Chapter.

–  Screw spindle -A- of assembly device -3066- into threaded piece in differential. –  Insert thrust piece -T10148- and secure with nut -B-.   Note t  The thrust piece -T10148- serves to protect the oil seal (right-side) and the gearbox from dirt. t  Instead of using the spindle -A-, an M8 x 105 mm bolt can also be screwed hand-tight into the threaded piece in the differential.

–  Carefully lift gearbox using engine and gearbox jack -V.A.G 1383 A- and ensure sufficient clearance between sleeve -1- and pressure plate -arrow- to prevent damage. –  Bring gearbox into position. –  Install bottom engine/gearbox securing bolts. Tightening torques → Anchor

–  Re-install flange shaft (right-side) and tighten countersunk bolt -arrow-. Tightening torque → Item –  Detach gearbox support -3282- with adjustment plate -3282/39- from gearbox after bolting gearbox and engine together.

–  Fit gearbox bracket -A- with new bolts -arrows- and tighten. Tightening torque → Item –  Install top engine/gearbox securing bolts. Tightening torques → Anchor –  Lift engine/gearbox assembly slightly via the spindles of support bracket -10 - 222 A-.

–  Align engine/gearbox in installation position. To do so, raise engine/gearbox until gearbox bracket makes full contact with gearbox mounting.   Caution The threads in the gearbox bracket can be damaged if the bolts are not inserted straight. Before fitting the bolts -arrows-, the gearbox bracket and the support arm of the gearbox mounting must be aligned absolutely parallel. If necessary, press rear part of gearbox up with engine and gearbox jack. –  Bolt gearbox bracket onto left engine/gearbox mounting using new bolts -arrows-. Tightening torque → Item   WARNING 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. –  Check adjustment of assembly mountings; adjust if necessary → Engine, mechanics; Rep. gr.10.

–  Fit pendulum support with new bolts -1 … 3- in accordance with installation instructions → Anchor. Tightening torques → Chapter –  Bolt drive shafts to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  If removed earlier, bolt on heat shield for drive shaft (right-side).

–  Install clutch slave cylinder -arrows-. Tightening torque → Item –  Install gearbox support -1-. Tightening torque → Item –  Install starter → Electrical system; Rep. gr.27.

–  Tighten nut -1- for bracket. –  Plug electrical connector -3- in at reversing light switch -F4-. Vehicles with start/stop system –  Attach connector -2- to gearbox neutral position sender -G701-.

Continued for all vehicles –  Secure cable support bracket -arrows-. Tightening torque → Item –  Install bracket -B- and attach clutch line -A-. Tightening torque → Item

–  Fit relay lever and secure with clip -arrow 1-. –  Attach gear selector cable to gearbox selector lever -A- and secure with securing clip -arrow 2-. –  Insert gate selector cable in cable end-piece and adjust selector mechanism → Chapter. –  A3 Cabriolet: Install frame for noise insulation → General body repairs, exterior; Rep. gr.50. –  Install front sections of wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation under engine/gearbox → General body repairs, exterior; Rep. gr.50. –  Fit front left wheel → Rep. gr.44.

–  Install battery tray -arrows- and battery → Electrical system; Rep. gr.27. –  Install complete air cleaner housing → Rep. gr.23.

Tightening torques Engine/gearbox securing bolts

Item	Bolt	Qty.	Nm
1	M 12 x 55	1	80
2	M 12 x 55	1	80
3 1)2)	M 12 x 150	1	80
4 1)2)	M 12 x 150	1	80
5	M 10 x 50	3	40
6	M 12 x 60	1	80
A	Dowel sleeves for centralising	2
l  1) Bolt with stud M8. l  2) Also starter to gearbox

Component	Nm
Bracket for electrical wiring at bottom starter bolt	23
Heat shield for drive shaft to cylinder block, M10	25