Audi Workshop Service and Repair Manuals

Installing gearbox Procedure Installation is carried out in reverse sequence; note the following: l  Tightening torques for installing gearbox → Anchor   Note t  Renew bolts which are tightened by turning through a specified angle. t  Renew seals, gaskets and self-locking bolts and nuts. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Hose connections and air pipes and hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. t  Re-attach all cable ties at the same locations when re-installing. –  Clean input shaft splines and splines of torsion damper. Remove corrosion and lubricate splines with only a very thin coating of grease → Electronic parts catalogue. It is important to remove excess grease.

–  If not already fitted, install dowel sleeves -A- for centralising engine/gearbox in cylinder block. t  Vehicles with 1.2/1.4 ltr. TFSI/1.6 ltr. TDI engine:

t  Vehicles with 1.6 ltr. MPI/1.8 ltr. TFSI engine:

Gearbox with stub shafts: If a new gearbox is not being installed: –  Renew O-ring -1- on stub shaft. –  Renew circlip -2- on stub shaft → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.

Continued for all vehicles: –  Check condition of needle bearing in crankshaft -arrow-; renew if necessary → Engine, mechanics; Rep. gr.13.   Note If the needle bearing in the crankshaft is damaged, the gears cannot be shifted correctly because the clutch is supported by this bearing.   Note

When installing a new gearbox, it may be necessary to change from the stub shaft version -A- to flange shaft version -B- → Electronic parts catalogue.

–  Make sure that the intermediate plate is engaged on the sealing flange -arrow A- and fitted on the dowel sleeves -arrows B-. t  Vehicles with 1.2 ltr. TFSI engine:

t  Vehicles with 1.4/1.8 ltr. TFSI engine, 1.6 ltr. MPI engine, 1.6 ltr. TDI engine: –  Carefully raise gearbox using engine and gearbox jack -V.A.G 1383 A- and position correctly using gearbox support -3282-.   Caution Risk of damage to selector lever cable. t  Carefully guide selector lever cable into cable support bracket when lifting gearbox. t  Do not bend or kink the selector lever cable. –  Secure gearbox to engine.

If the gearbox was sealed with oil-tight plugs, e.g. after a gearbox repair or when installing a replacement gearbox: –  Remove both plugs from breathers -arrows- and install breather caps.

Continued for all vehicles: Install assembly mounting as follows: –  Fit gearbox support -1- between gearbox and support arm of gearbox mounting. –  Bolt gearbox support to gearbox. –  Pull gearbox up to support arm of gearbox mounting using spindle of support bracket. –  Hand-tighten bolts -arrow- securing gearbox mounting to gearbox support initially. –  Detach gearbox support -3282- from gearbox. Gearbox with stub shafts: –  Press drive shafts onto stub shafts of gearbox until circlip snaps into place → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. Gearbox with flange shafts: –  Install flange shaft (right-side) → Chapter. –  Secure drive shafts to flange shafts on gearbox → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.

Continued for all vehicles: –  Install pendulum support → Chapter. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. gr.26. –  Install starter → Electrical system; Rep. gr.27.

–  Check adjustment of assembly mountings → Engine, mechanics; Rep. gr.10. –  Detach support bracket -10 - 222 A- from engine. –  Check adjustment of selector lever cable and adjust if necessary → Chapter. –  Install battery tray and battery → Electrical system; Rep. gr.27. –  Fill cooling system → Engine, mechanics; Rep. gr.19. Tightening torques (installing gearbox)   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques is ± 15%.

Dual clutch gearbox to 1.2/1.4 ltr. TFSI engine:

Item	Bolt	Nm
1, 8	M10x50	40
2, 6, 7	M12x65	80
3, 4, 5	M12x55	80
A	Dowel sleeves for centralising

Dual clutch gearbox to 1.6 ltr. MPI engine:

Item	Bolt	Nm
1, 3	M12x55	80
2	M12x170	80
4	M12x80	80
5, 6, 7	M10x50	40
8	M12x90	80
A	Dowel sleeves for centralising

Dual clutch gearbox to 1.8 ltr. TFSI engine

Item	Bolt	Nm
1, 3	M12x55	80
2	M12x155	80
4, 8	M12x65	80
5	M12x50	80
6, 7	M10x50	40
A	Dowel sleeves for centralising

Dual clutch gearbox to 1.6 ltr. TDI engine:

Item	Bolt	Nm
1, 3, 10	M12x55	80
5, 9	M12x70	80
6 … 8	M10x50	40
A	Dowel sleeves for centralising

Additional tightening torques: l  → Chapter „Exploded view - assembly mountings“.