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. –  Unclip air intake hose from air duct -arrows-.

–  Unplug electrical connector at intake air temperature sender 2 -G299-. –  Detach vacuum hose -1- from actuator for intake air preheater.

–  Pull dipstick -1- out of guide tube. –  Remove engine cover panel with air cleaner housing -arrows-. –  Re-insert dipstick in guide tube.

Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Remove battery → Rep. Gr.27. –  Remove battery tray -arrows- (detach front of battery tray from air duct if applicable).

Metal relay lever: –  Detach securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-. –  Detach securing clip -arrow 2- for gate selector cable from relay lever -B-. –  Pull gate selector cable and gear selector cable off joint pins. –  Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever: –  Detach relay lever (with detent catch) / relay lever (with clip) from gearbox selector lever → Fig. / → Fig.. Continued for all vehicles: –  Remove nut -arrow 4- and detach gearbox selector lever -A-.

–  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.

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

–  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). –  Hook spindle of support bracket into engine lifting eye (left-side). –  Take up weight of engine with spindle; do not lift.

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

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

–  Unplug electrical connector -4- for reversing light switch -F4-. –  Unplug electrical connector -2- for Lambda probe -G39- and electrical connector -1- for exhaust gas temperature sender 1 -G235- and unhook from bracket. –  Remove nut -arrow- and detach bracket -3- from stud together with electrical wiring. –  Tie bracket and electrical wiring to the front. –  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up drive shafts.   Note

To prevent damage, the flexible couplings in the front exhaust pipe must not be bent further than 30°. –  Remove nuts -2- and -3- from exhaust system flange. –  Detach exhaust system at flange. –  Unscrew bolts -1- and -5- of bracket -4- for exhaust system.

–  Remove bolts -4- and -6 ... 8- from engine/gearbox flange. –  Slacken bolt -5- and leave it in position only finger-tight. –  Remove starter.   Note The two lower bolts on engine/gearbox flange -6- and -7- remain in place on engine.

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

–  Remove bolts -arrows- from gearbox mounting.

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

–  Unbolt gearbox support from gearbox -arrows-.

–  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.