Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 1.4 ltr. TFSI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/46-

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

Note All cable ties which are released or cut open during removal must be fitted in the same position when installing.

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

–  Disconnect hose -1- at air cleaner housing. –  If fitted, unplug connector -2- at air cleaner housing. –  Release spring clips -4- and detach air intake hose. –  Remove bolt -3-. –  Take out air cleaner housing.   WARNING Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  Detach cover above battery (press release tab -arrow-).

–  With ignition switched off, disconnect battery earth strap -arrow-.

–  Remove battery → Electrical system; Rep. Gr.27. –  Remove battery tray -arrows-.

–  Detach coolant hose -1- from engine cover panel. –  Pull dipstick -2- out of guide tube. –  Remove engine cover panel -arrows-. –  Re-insert dipstick -2- in guide tube.

–  Pull off securing clips -arrow 1- and -arrow 2-. –  Pull gate selector cable and gear selector cable off joint pins. –  Pull off securing clip -arrow 3- and remove gate relay lever -B-. –  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.   WARNING Do not depress clutch pedal after removing slave cylinder.

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

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

Continued for all vehicles: –  Remove bolts -1 ... 4- from engine/gearbox flange.

–  Set up support bracket -10-222 A- on wing mounting flanges. –  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 noise insulation → General body repairs, exterior; Rep. Gr.50.

–  Remove front section of front wheel housing liner (left-side) → Rep. Gr.66.

–  Unplug electrical connector -4- for reversing light switch -F4-. –  Remove nut -arrow- and detach bracket -3- from stud together with electrical wiring -1- and -2-. –  Remove bolts -arrows- and detach starter.

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

–  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up drive shafts. –  Remove engine/gearbox securing bolt -A- above flange shaft (right-side).   Note

To prevent damage, the flexible couplings in the front exhaust pipe must not be bent further than 30°. –  Remove bolts -arrows-.

–  Remove nuts -1- from exhaust system flange. –  Unclip Lambda probe wire -arrows-. –  Detach front exhaust pipe -2- from catalytic converter.

–  Remove the two bolts -arrows 1- from gearbox mounting.

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

–  Unbolt gearbox bracket from gearbox -arrows 2-.

–  Secure support -T10036- to subframe, using two M6x20 bolts -1- and one washer -2-. –  Secure engine support -3300 A- and push engine to the front, ensuring that there still is enough clearance to radiator cowl. To remove gearbox “0AJ” set up gearbox support -3282- with adjustment plate -3282/46-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/46- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate. –  Bolt on support elements as illustrated on adjustment plate. –  Place engine and gearbox jack -V.A.G 1383 A- under vehicle; arrow symbol on adjustment plate points to front of vehicle. –  Align adjustment plate parallel with gearbox. Pin -arrow 1- (illustration 10836) should be flush with guide of gearbox support.

–  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox.

–  Secure bolt -3282/45- with a nut M8 to gearbox -arrow 2-. –  Unscrew engine/gearbox securing bolt -A-.

–  Remove engine/gearbox securing bolts -arrows- in area of engine sump. –  Press gearbox off dowel sleeves. –  Take care not to damage intermediate plate on engine. –  Carefully push engine towards front (2nd mechanic required). –  Pivot differential side of gearbox upwards using spindles on gearbox support -3282-.

–  Turn gearbox in area of cover for 6th gear downwards as illustrated -arrow 1-.

–  Then carefully guide gearbox with right-hand flange shaft past flywheel/intermediate plate as illustrated -arrow 2-. –  Lower gearbox, observing subframe at the same time -arrow 1-. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-.   Note Pay attention to all pipes/hoses/wiring when lowering gearbox.