Audi Workshop Service and Repair Manuals

Installing gearbox Procedure   Note 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.   Note 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 stud with MoS2 grease. –  Raise gearbox carefully and move to installation position using gearbox support -3282-. –  Bolt gearbox onto engine.

–  Insert cover plate -2- so that that bottom lug engages on cylinder block and secure at the top with bolt -1-.   Note Shown in illustration with gearbox removed.

–  Install gearbox support with new bolts -arrows-. Tightening torque → Item

–  Tighten bolts -arrows- on gearbox mounting finger-tight to start with. –  Use new bolts. –  Install pendulum support → Chapter. –  Bolt drive shafts to flange shafts → Rep. Gr.40.. –  Install exhaust system and perform stress-free alignment → Rep. Gr.26. –  Check mountings of engine/gearbox assembly for correct adjustment, and re-adjust if necessary → Rep. Gr.10.. –  Tighten bolts on gearbox mounting → Chapter. The remaining installation steps are carried out in reverse sequence; note the following: –  Install clutch slave cylinder → Chapter. –  Attach and adjust selector cables at gearbox → Chapter. –  Fill up oil in gearbox and check oil level → Chapter. –  Install noise insulation. –  Install wheel and tighten wheel bolts → Rep. Gr.44. –  Install battery tray and battery → Rep. Gr.27. –  Install air cleaner housing → Rep. Gr.24.

Tightening torques

Item	Bolt	Nm
1, 2	M12×65	80
3 → Note, 4 → Note	M12×135	80
5 … 7	M10×60	40
8	M12×90	65

1)  Bolt with stud M8 A -  Dowel sleeves for centralising

Heat shield for drive shaft (right-side) –  Tighten bolts -arrows- to 35 Nm.