Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 1.6 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Gearbox support -3282-

t	Pin -3282/29-

t	Adjustment plate -3282/39-

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

t  Thrust piece -T10148-

t  Spindle from assembly device -3066- or M8 x 105 bolt t  Grease for clutch plate splines -G 000 100- 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 → Electrical system; Rep. gr.27. –  Remove air cleaner housing completely → Rep. gr.23.

–  Remove battery → Electrical system; Rep. gr.27. –  Remove battery tray -arrows- (detach front of battery tray from air duct if applicable).

–  If fitted, cut open cable tie -arrow- for protective cover. –  Unplug electrical connector -2-. –  Push back protective cover and disconnect B+ wire from starter solenoid. –  Disconnect earth wire -1-. –  Remove top starter mounting bolt.

–  Pull locking mechanism forwards in direction of -arrow 1- onto stop and then turn in direction of -arrow 2- to lock. –  Press relay lever forwards (in direction of -arrow 3-) and pull out gate selector cable.

–  Remove clip -arrow 1- and take off relay lever together with cable end-piece. –  Detach securing clip -arrow 2- and pull gear selector cable off gearbox selector lever -A-.

–  Detach cable support bracket from gearbox -arrows-.   Note Items -A- and -B- can be disregarded. –  Tie cables with cable support bracket to one side.

–  Move pipe -2- clear at bracket -1-. –  Unscrew bolt -3- and detach bracket.

–  Detach gearbox support -1-. –  Remove clutch slave cylinder -arrows- and place to one side; do not disconnect pipe.   Caution Do not depress clutch pedal after removing clutch slave cylinder.

–  Remove engine/gearbox securing bolts -1- and -2- (accessible from above).

–  Press release tabs and disconnect crankcase breather hose -1-. –  Move vacuum hoses clear -arrows-. –  Remove bolt -2-, pivot air intake hose to the rear and detach from turbocharger.

–  Assemble support bracket -10 - 222 A- as shown in illustration and set up on wing panel flanges. –  Engage lifting hooks of spindles on engine lifting eyes (left and right). –  Take up weight of engine/gearbox assembly with spindles; do not lift. –  Raise vehicle.

–  Remove front left wheel. –  Remove noise insulation -1- → General body repairs, exterior; Rep. gr.50.

–  A3 Cabriolet: Remove noise insulation frame -arrow- → General body repairs, exterior; Rep. gr.50.

–  Remove front section of wheel housing liner on both sides → General body repairs, exterior; Rep. gr.66.

Vehicles with start/stop system –  Unplug electrical connector -2- from gearbox neutral position sender -G701-. Continued for all vehicles –  Unplug electrical connector -3- at reversing light switch -F4-. –  Remove nut -1- and detach bracket for wiring. –  Remove bottom starter mounting bolt and take out starter.

–  Release hose clips -1- and -2- and remove air hose.

–  If fitted, detach heat shield for drive shaft (right-side) -arrows-. –  Unbolt drive shafts (left and right) from flange shafts on gearbox. –  Lift drive shafts (left and right) up and secure with cable tie.   Note Make sure you do not damage surface coating on drive shafts.

–  Remove bolt -arrow- securing flange shaft (right-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever. –  Detach flange shaft.   Note Before removing flange shaft, check oil seal for damage. A leaking oil seal must be renewed when fitting flange shaft.

–  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.

–  Remove bolts -1, 2, 3- and detach pendulum support.

–  Remove bolts -arrows- on gearbox mounting.

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

–  Unbolt gearbox bracket -A- from gearbox -arrows-.

To remove gearbox „0A4“ set up gearbox support -3282- with adjustment plate -3282/39-. –  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. –  Screw support elements-A- and pin -3282/29- (-C-) into adjustment plate, as illustrated. –  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 -3282/39- parallel to gearbox and lock safety support on gearbox. –  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox. –  Support gearbox from underneath by raising engine and gearbox jack -V.A.G 1383 A-.

–  Remove remaining engine/gearbox securing bolts -5- and -6-. –  Press gearbox off dowel sleeves. –  Pull gearbox off engine.

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

–  If necessary, re-install flange shaft (right-side) and tighten countersunk bolt -arrow- to 25 Nm. Transporting gearbox → Chapter