Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/31-

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

t  Removal lever -80 - 200- for vehicles from 06.2008 onwards

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. –  With ignition switched off, disconnect battery earth strap -arrow- → Rep. Gr.27.

–  Remove front left wheel. –  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (left-side) -fasteners 1 ... 3-.

–  Detach air hose -arrow- at bottom of resonator.

–  Detach electrical connector -3- for reversing light switch. –  Remove nut -1- and detach bracket -2- from stud together with electrical wiring. –  Move bracket and wiring clear to the side.

–  Unbolt heat shield for right-side drive shaft -arrows-. –  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up drive shafts.

–  Unbolt support bracket for exhaust system -arrows-.

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

–  Remove engine cover panel -arrows-.

–  Disconnect hoses -1-, -3- and -4-. –  Release spring clips -2- and -5-, and remove air intake hose.

–  Remove air cleaner housing completely → Rep. Gr.24. –  Disconnect air hose (going to resonator) at lock carrier and remove.

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

–  Unscrew earth wire -1-. –  Detach electrical wires -2- and -3- at starter and move them clear. –  Move wiring clear.

Metal relay lever: –  Detach securing clips -1- and -2- on both cables. –  Detach cable end-pieces from gearbox selector lever and relay lever.

Plastic relay lever: l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing relay lever. –  Pull locking mechanism forwards in direction of -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock. –  Then press relay lever forwards (in direction of -arrow 3-). l  Detach cable end-piece only when relay lever is removed → Fig..

Continued for all vehicles: –  Detach cable support bracket from gearbox -arrows- and place to one side.

–  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 bolts -1 ... 3- from engine/gearbox flange.

Vehicles from 06.2008 onwards: –  Lever clip off sealing element using removal lever -80 - 200- and fold up sealing element.

Continued for all vehicles: –  Set up support bracket -10 - 222 A- on wing mounting flanges (vehicles up to 05.2008) or on body flanges (vehicles from 06.2008 onwards). l  Spindles face to the front. –  Disconnect crankcase breather hose from cylinder head cover. –  Engage spring hooks of spindles on lifting eyes. –  Take up weight of engine evenly with both spindles; do not lift.

–  Remove bolts -arrows- from gearbox mounting.

–  By adjusting spindles on support bracket -10 - 222 A-, lower gearbox by distance -a-. l  Distance a = 70 mm

–  Unbolt gearbox support from gearbox -arrows-.

–  Remove bolt -1- with gearbox fitted. –  Lift out cover plate -2-.   Note Shown in illustration with gearbox removed.

–  Remove bolts -4- and -6 ... 8- from engine/gearbox flange. –  Remove starter.   Note Slacken bolt -item 5- and leave it in position only finger-tight.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/31- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support to coincide with holes in adjustment plate. –  Screw in support elements -A- as shown on adjustment plate. –  Run engine/gearbox jack -V.A.G 1383 A- under vehicle; arrow symbol -B- faces forward.

–  Align adjustment plate -3282/31- parallel to gearbox and lock safety support on gearbox as illustrated. –  Remove the last engine/gearbox securing bolt -arrow-.

–  Pull gearbox off dowel sleeves and about 60 mm away from engine. –  Move the gearbox into the position shown. l  Flange shaft must clear dowel sleeve on engine -arrow 2- when gearbox is lowered. l  Gearbox housing must clear subframe -arrow 1- when gearbox is lowered.