Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Hose clamps, up to 25 mm -3094-

t	Gearbox support -3282-

t	Adapter -VW 771/40-

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

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

t  Pin -3282/29-

t  Adjustment plate -3282/33-

t  Stepladder -VAS 5085- t  Grease for clutch plate splines -G 000 100- t  Grease -G 000 450 02- t  Universal grease -G 052 735- t  Bolt M10x20

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 wire -arrow- → Electrical system; Rep. Gr.27.

Unit injector engine with one-piece engine cover panel: –  Pull dipstick -1- out of guide tube. –  Lift engine cover panel at the sides -arrows 2- and pull out from the front -arrow 3-. –  Re-insert dipstick in guide tube.

Unit injector engine with two-piece engine cover panel: –  Evenly lift off engine cover panel (outer section -1- and inner section -2-).

Common rail engine: –  Remove engine cover panel -arrows-.

Continued for all vehicles: –  Pull off cover for air duct (release retaining clips -arrows- on the sides).

–  Pull off bottom section of air duct (release retaining clips -arrows-). –  Remove bottom section of air duct with air intake hose.

–  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).

–  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin. Metal gate relay lever: –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin.

Plastic gate 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 gate relay lever forwards (in direction of -arrow 3-). l  Detach cable end-piece only when gate relay lever is removed → Fig..

Continued for all vehicles: –  Detach cable support bracket from gearbox -arrows-; then move to one side and tie up together with selector cables.

–  Unscrew earth wire -1- from upper starter bolt.   Note Connector -2- and wire -3- remain in position on starter. –  Unscrew top starter bolt -1-.

–  If a plastic pipe is installed between clutch master cylinder and slave cylinder, clamp off supply hose to clutch master cylinder using hose clamp up to 25 mm -3094-.

–  If a pipe/hose assembly is installed between clutch master cylinder and slave cylinder, clamp off hose -A- using hose clamp up to 25 mm -3094-.   Note -Arrow- can be disregarded.   Note

t  In the following steps make sure that no brake fluid escapes onto the starter or onto the gearbox below. If this does happen, clean the affected area thoroughly. t  Place a cloth underneath to catch escaping brake fluid. –  Release clip -3- with a screwdriver and disconnect pipe/hose assembly -1- or plastic pipe from connection -4-. –  Detach pipe/hose assembly from bracket and move clear to the side.   Note -Item 2- can be disregarded.   Caution Do not operate clutch pedal after disconnecting pressure line from slave cylinder.

–  Remove bolts -1- from engine/gearbox flange. –  Then remove upper securing bolt from starter -2-.

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- with adapters -10 - 222 A /3- on wing mounting flanges. –  Engage hooks of spindles on lifting eyes. –  Partly take up weight of engine with spindles, but do not lift.

–  Remove noise insulation (centre) by releasing fasteners -1 ... 3-.

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

–  If fitted, remove front left vehicle level sender -G78--arrows-.

Vehicles with start/stop system: –  Unplug electrical connector -arrow- from gearbox neutral position sender -G701-.

Continued for all vehicles: –  Unplug electrical connector at reversing light switch -F4--2-. –  Remove nut -1- and detach bracket from bottom starter bolt with electrical wiring. –  Unscrew bottom bolt securing starter -1-. –  Place starter to side onto longitudinal member.

–  Detach connection -arrow- at air pipe (left-side).

–  Remove exhaust system bracket from subframe -arrows-.

–  Disconnect exhaust system at clamp -arrows-. –  Tie up the front exhaust pipe.   Note To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.

–  Detach connector -1- from oil level and oil temperature sender -G266-.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unbolt propshaft with flexible coupling from bevel box -arrows- (counterhold triangular flange with suitable lever).

–  Remove bolts -2- and -3- for pendulum support on gearbox.

–  Push engine/gearbox assembly slightly towards front of vehicle and then pull propshaft off bevel box.   Caution The seal -arrow- in the propshaft flange can be damaged. Push propshaft towards the rear and to the right as far as possible.   Note If seal is damaged propshaft must be renewed. –  Lift propshaft up and secure with wire. –  Before removal, fix subframe in position → Rep. Gr.40. –  Remove subframe with pendulum support → Rep. Gr.40. –  Remove suspension bracket with wishbone (left-side) → Rep. Gr.40.

–  Unbolt heat shield for drive shaft (right-side) from bevel box -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts.

Vehicles without diesel particulate filter: –  Unscrew bolts for gearbox carrier on engine and bevel box -arrows 1- and -arrows 2-. –  Remove gearbox carrier.

–  If fitted, remove exhaust system support -A- → Rep. Gr.26.

Vehicles with diesel particulate filter: –  Remove nuts -1- and -2- and detach bracket for particulate filter.

–  Remove bolts for gearbox carrier on engine and bevel box -arrows 1 ... 3-.   Note Do not remove gearbox carrier until gearbox has been pressed off engine.

Continued for all vehicles: –  If fitted, remove small cover plate -A- at rear of bevel box -arrow-.

–  Remove bolts -arrows- on gearbox mounting.

–  By adjusting spindles on support bracket -10 - 222 A-, lower gearbox by distance -a-. l  Dimension -a- = 60 mm.

–  Unbolt gearbox support from gearbox -arrows-.

Metal gate relay lever: –  Pull securing clip -arrow- off gate relay lever -1- and remove gate relay lever.

Plastic gate relay lever: –  Press in detent -arrow 1- as far as stop and remove gate relay lever together with cable end-piece (move relay lever in normal direction of operation).   Note -Item 2- can be disregarded.

Continued for all vehicles: –  Remove engine/gearbox connecting bolts (bottom) -1- (on engine side) and -2-.   Note Do not loosen bolt -3- at this stage.

To remove gearbox “02Q” set up gearbox support -3282- with adjustment plate -3282/33-. –  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. –  Bolt on support elements -A-, as illustrated on adjustment plate. –  Screw in pin -3282/29- instead of support element-C-. –  Place engine and gearbox jack under vehicle; arrow symbol -B- on adjustment plate points to front of vehicle. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox.

–  Secure adapter -VW 771/40- in tapped hole of gearbox housing, as shown in illustration. –  Secure gearbox to gearbox support -3282- with bolt M10x20 -A-.

–  Unscrew last engine/gearbox securing bolt -3-. –  Press gearbox off engine (dowel sleeves).

Vehicles with diesel particulate filter: –  Remove gearbox carrier -A-. Continued for all vehicles: –  Carefully lower gearbox.   Note When lowering gearbox make sure the electromechanical power steering is not damaged.