Audi Workshop Service and Repair Manuals

Removing gearbox (vehicles with 1.8 ltr. TFSI 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 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-. –  Remove bolts -2- for cable support bracket.   Caution Risk of damage to selector lever cable. Do not bend or kink the selector lever cable.

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

–  Remove bolts -1- and -2- and detach starter from gearbox.

–  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. l  Spindle faces to the rear. –  Hook spindle of support bracket into engine lifting eye (left-side). –  Take up weight of engine with spindle; 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 noise insulation → General body repairs, exterior; Rep. gr.50.   Note Depending on version, different types of noise insulation may be fitted.

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

Continued for all vehicles –  Remove front section of front wheel housing liner on both sides → General body repairs, exterior; Rep. gr.66.   Note Depending on version, different types of wheel housing liner may be fitted.

–  Remove bolts -1- from above.   Note -Items 2 and 3- can be disregarded.

–  Release hose clip -2-. –  Remove bolt -4-. –  Unplug electrical connector -arrow- and move wiring clear.   Note t  Bolt -1- will be loosened later. t  -Item 3- can be disregarded.

–  Lift retaining clip -1- and disconnect air hose from charge air cooler.   Note -Item 2- can be disregarded.

–  Unplug electrical connector -2-. –  Remove bolts -3- and take out radiator cowl from below.

–  Remove bolt -1- and detach air pipe from below.   Note -Item 3- can be disregarded.

–  Take electrical connector -arrow- out of bracket on gearbox.

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. –  Pull catch upwards -arrow- and unplug electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. –  Remove nuts -2- and -3- and detach bracket for electrical wiring from gearbox.

–  Unplug electrical connector -2- for radiator outlet coolant temperature sender -G83-.   Note Catch escaping coolant in a clean container for disposal or re-use. –  Place drip tray for workshop hoist -VAS 6208- under the engine. –  Detach coolant hose -1- (pull out retaining clip and let coolant drain off).

Caution Risk of damage to flexible joint. The flexible joint in the front exhaust pipe must not be bent further than 10°. –  Disconnect exhaust system at clamp -arrows-. –  Push clamp towards rear and set front exhaust pipe down on cross member on vehicle underside.

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

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).

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

–  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 -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.

–  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.

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-.