Audi Workshop Service and Repair Manuals

Removing gearbox (vehicles with 2.0 ltr. TDI common rail engine)

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Removal lever -80 -

t	Gearbox support -3282-

t	Pin -3282/29-

t	Adjustment plate -3282/42 A-

t	Engine support -3300 A-

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

t  Used oil collection and extraction unit -V.A.G 1782-

t  Engine bung set -VAS 6122-

t  Support -T10036- Removing   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. t  Observe notes on direct shift gearbox 02E → Chapter. t  Re-attach all cable ties at the same locations when re-installing. –  Shift selector lever into position “P”.

–  Remove noise insulation -1- → 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 both front wheels. –  Remove front section of front wheel housing liner (left-side) → General body repairs, exterior; Rep. Gr.66.   Note Depending on version, different types of wheel housing liner may be fitted. –  Drain cooling system → Engine, mechanics; Rep. Gr.19. –  Remove radiator cowl → Engine, mechanics; Rep. Gr.19. –  Remove starter → Electrical system; Rep. Gr.27.

–  Remove battery → Electrical system; Rep. Gr.27. –  Remove bolts -arrows- and take out battery tray -1- .

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

–  Disconnect earth wire -3-.   Caution The control unit (mechatronic unit) can be damaged by electrostatic discharge. Do not touch contact pins in gearbox connector with bare hands. –  Touch vehicle earth with your hand (without gloves) to discharge any static electricity. –  Turn fastener anti-clockwise and unplug electrical connector -4- on gearbox.   Note Items marked -1, 2- and -arrow- can be disregarded.

–  Move clear wiring harnesses -arrows- and electrical connector -1- at bracket.

–  Release hose clips -arrows- and disconnect coolant hoses from gear oil cooler. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove all engine/gearbox securing bolts which are accessible from above.

–  Detach seal -1-.   Note -Item 2- can be disregarded.

–  Swivel bonnet seal -1- inwards on left and right -arrow- –  Press off fastening element -2- with removal lever -80 - 200-. –  Move clear bonnet seal and press to the side.

–  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. –  Engage hooks on spindles of support bracket into engine lifting eyes. –  Take up weight of engine evenly with spindles; do not lift.

–  If fitted, remove guard plate -A- on underside of gearbox -arrows-.

–  Remove nuts -arrows- and detach front cross member on vehicle underside.   Note To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°. –  Loosen nuts for clamp -1- and move clamp towards rear.

–  Unbolt bracket for exhaust system -arrows- and pull bracket off retaining pins.

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

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Unbolt drive shafts (left and right) from flanges on gearbox.

–  If fitted, unscrew nuts on bracket for front left vehicle level sender -G78--arrows-.

–  Remove nuts -arrows- securing swivel joint (left-side). –  Disengage swivel joint from wishbone.

–  Swivel suspension strut (left-side) outwards and support with extension -2024 A /1- as shown in illustration.   WARNING Secure locking pin and swivel joint with retaining clip -arrow- and nut -1-.

–  Remove bolts -1- for cable support bracket. –  Pull off securing clip -3--arrow- and detach selector lever cable from gearbox.   Note -Item 2- can be disregarded.

–  Remove bolts -1- and -2- and detach gearbox support -A-.

–  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- = 100 ... 110 mm

–  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 M6x20 mm bolts -arrows-.

–  Bolt engine support -3300 A- to support -T10036-. –  Press engine towards front of vehicle using spindle of engine support; note the following: l  Alternator should only make light contact with refrigerant pipe. l  Air conditioner compressor should only make light contact with connection for refrigerant pipe.   Note

Before removing flange shaft, check oil seal for damage. A leaking oil seal must be renewed when fitting flange shaft. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove bolt securing flange shaft (left-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever. –  Pull out flange shaft and spring.   Note

Before removing flange shaft, check oil seal for damage. A leaking oil seal must be renewed when fitting flange shaft. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Using socket and extended bit -T10107-, remove bolt securing flange shaft (right-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever.

To remove the direct shift gearbox 02E, set up gearbox support -3282- with adjustment plate -3282/42A- and place on engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate -3282/42A-. –  Secure support elements as illustrated on adjustment plate -3282/42A-. However, use “retainer plate with drilling” as front support element. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. l  The arrow symbol on the adjustment plate points in the direction of travel. –  Align gearbox support -3282- parallel with gearbox. –  Screw pin -3282/29- into gearbox. –  Secure “retainer plate with drilling” firmly to gearbox as illustrated -arrow-. –  Insert last support element in gearbox as illustrated. –  Support gearbox by lifting from underneath with engine and gearbox jack -V.A.G 1383 A-.

–  Remove remaining engine/gearbox securing bolts -5 … 9-. –  Press gearbox off dowel sleeves. –  Carefully lower gearbox using engine and gearbox jack -V.A.G 1383 A-, taking care not to trap wiring or other connections. –  While lowering gearbox, change position of gearbox using spindles on gearbox support -3282-.