Audi Workshop Service and Repair Manuals

Removing gearbox (vehicles with 1.6 ltr. TDI engine)

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Removal lever -80 - 200-

t	Gearbox support -3282-

t	Pin -3282/29-

t	Adjustment plate -3282/59-

t	Engine support -3300 A-

t	Extension -2024 A /1-

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

t	Stepladder -VAS 5085-

t	Drip tray for workshop hoist -VAS 6208-

t	Support -T10036-

t	Tensioning strap -T10038-

Procedure   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. t  Observe notes on dual clutch gearbox 0AM → Chapter. t  Re-attach all cable ties at the same locations when re-installing. –  Shift selector lever into position „P“.

–  Pull off cover -1- for air duct (release retaining clips -arrows- on the sides).

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

–  Unplug electrical connector -1- from air mass meter -G70-. –  Remove air hose -2-. –  Remove bolt -4- and remove air cleaner housing.   Note -Item 3- can be disregarded.

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 → Electrical system; Rep. gr.27. –  Remove bolts -arrows- and detach battery tray.

–  Pry selector lever cable -2- off gearbox selector lever using removal lever -80 - 200-. –  Pull off securing clip -1- for selector lever cable.   Caution Risk of damage to selector lever cable. t  Guide selector lever cable out of cable support bracket when lowering gearbox. t  Do not bend or kink the selector lever cable. –  Remove bolts -2- for cable support bracket.

–  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Move clear vacuum hoses -arrows- at air pipe. –  Release hose clip -2- and detach air pipe.

–  Remove noise insulation -1- → Rep. gr.50.

Audi A3 Cabriolet –  Remove noise insulation frame -arrow- → General body repairs, exterior; Rep. gr.50.

Continued for all vehicles –  Remove bolts -arrows-. –  Move clear coolant hose at air pipe (left-side).   Note -Items 1 ... 5- can be disregarded.

–  Unplug electrical connector -2-. –  Push back dust boot -1- and disconnect „B+ wire“ from starter solenoid. –  Remove nut -3- for earth wire.

–  Remove bolts -3, 4, 5- securing gearbox to engine.

–  Lever clip off sealing element using removal lever -80 - 200- and fold up sealing element.

–  Set up support bracket -10 - 222 A- on body flanges, as shown in illustration. –  Hook spindles of support bracket onto engine lifting eyes. –  Take up weight of engine with spindles; do not lift.   WARNING Risk of scalding from hot steam and hot coolant. t  The cooling system is under pressure when the engine is hot. t  Cover filler cap on expansion tank with a cloth and open carefully to release pressure. –  Open filler cap on expansion tank.

–  Remove both front wheels. –  Remove front section of front wheel housing liner on both sides → Rep. gr.66.

Caution Risk of irreparable damage to gearbox components. Never touch the contacts in the gearbox connector with your hands. Static discharge can seriously damage the control unit and mechatronic unit. –  Touch a suitable earthed object with your hand (without gloves) to discharge any static electricity. –  Unplug electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. –  Take electrical connectors -2- and -3- out of bracket and unplug. –  Remove all retainers from mechatronic unit for dual clutch gearbox -J743-. –  Move electrical wiring harness clear on gearbox.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- for electrical wiring leading to oil level and oil temperature sender -G266- at subframe.

–  Remove bolts -arrows- and pull bracket for exhaust system off pins on front exhaust pipe.

–  Gearbox with flange shafts: unbolt drive shafts (left and right) from gearbox flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  Remove nuts -arrows- securing swivel joint (left and right). –  If fitted, unscrew nut on bracket for front left vehicle level sender -G78-. –  Disengage swivel joints from wishbones. –  Use assembly lever to press drive shafts (left and right) off gearbox.

–  Swivel suspension strut (left and right) outwards and support with extension -2024 A /1-, as shown in illustration.   WARNING Risk of accident if parts of support are not properly secured. Secure locking pin and swivel joint with retaining clip -arrow- and nut -1-.

–  Remove bolts -1, 2, 3- and detach pendulum support.

–  Remove bolts -arrows- for assembly mounting on gearbox.

–  Lower engine/gearbox assembly using spindle of support bracket -10 - 222 A- until distance -a- is obtained between gearbox housing and gearbox mounting. l  Dimension -a- = 40 mm

–  Remove bolts -arrows- and detach gearbox support.

–  Remove bolts -arrows- and detach heat shield -1-.

–  Drill two 7 mm diameter holes in support -T10036-, as illustrated. l  Dimension -a- = 70 mm l  Dimension -b- = 98 mm. l  Dimension -c- = 11 mm.

–  Bolt support -T10036- onto subframe with two M6x20 mm bolts -arrows-.

–  Bolt engine support -3300 A- to support -T10036-. –  Press engine 10 to 15 mm towards front of vehicle using spindle of engine support. l  Alternator should only make light contact with refrigerant pipe. l  Air conditioner compressor must not make contact with connection for refrigerant pipe.

To remove dual clutch gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59-. –  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate -3282/59-. –  Secure support elements as illustrated on adjustment plate -3282/59-. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. The -arrow symbol- on the adjustment plate -3282/42- points in the direction of travel. –  Align gearbox support -3282- parallel with gearbox. –  Screw pin -3282/29- into gearbox. –  Insert last support element in gearbox as illustrated. –  Use tensioning strap -T10038- to secure gearbox. –  Support gearbox by lifting from underneath with engine and gearbox jack -V.A.G 1383 A-.

–  Remove remaining bolts -1, 2, 6, 7, 8- securing gearbox to engine. –  Press gearbox off dowel sleeves. –  Pull gearbox off engine. –  Carefully lower gearbox using engine and gearbox jack -V.A.G 1383 A-. –  Guide selector lever cable out of cable support bracket while lowering gearbox.   Note Do not bend or kink the selector lever cable. –  While lowering gearbox, change position of gearbox using spindles on gearbox support -3282-.