Audi Workshop Service and Repair Manuals

Installing gearbox Procedure Installation is carried out in reverse sequence; note the following:   Note t  Renew self-locking nuts and bolts. t  Always renew seals/gaskets, oil seals and O-rings. t  Re-attach all cable ties at the same locations when re-installing. –  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Do not grease guide sleeve. l  It should be possible to push the clutch plate back and forth slightly on the input shaft. –  Check whether dowel sleeves for aligning gearbox with engine are in the engine flange. Insert if necessary → Anchor. –  Check clutch release bearing for wear and renew if necessary. –  Checking and servicing release bearing with glued plastic ring → Fig. –  Checking release bearing with mechanically attached plastic ring → Fig. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox. –  If fitted, place intermediate plate on dowel sleeves at engine flange.

Vehicles with V6 TDI engine: –  Before installing gearbox, check that brace -B- is still moved to one side -direction of arrow-.

Continued for all vehicles: –  Lightly lubricate surface where operating rod and clutch release lever -arrow B- make contact with copper grease -Z 381 351 TE-. –  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for hose/pipe assembly. –  Guide slave cylinder -1- into opening in gearbox housing keeping it as straight as possible (without tilting operating rod -arrow A-) and insert in recess -arrow B- on clutch release lever -3-.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the operating rod -arrow A- will be guided past the clutch release lever -3-. –  Secure slave cylinder with new bolt -2-. –  When aligning the gearbox with the engine, turn crankshaft back and forth slightly to make it easier to insert the gearbox input shaft splines into the clutch plate.   Caution t  After installing the slave cylinder press the clutch pedal carefully. t  If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. t  The operating rod of the slave cylinder is likely to have been guided past the clutch release lever. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. t  For comparison: normal pedal force is approx. 115 N. –  Install starter and tighten left and right engine/gearbox connecting bolts.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -1- between lifting column and gearbox). –  Use engine and gearbox jack to lift gearbox up slightly.

–  Tighten the 3 bottom engine/gearbox securing bolts -arrow-. –  Lower gearbox slightly.

–  Bolt tunnel cross member onto gearbox mounting -3-. –  Raise gearbox using engine and gearbox jack -V.A.G 1383 A- and secure tunnel cross member to body using bolts -1- and -2- → Rep. Gr.40. –  Bolt drive shafts to flange shafts → Rep. Gr.40. –  Install exhaust system and align it so it is stress-free → Rep. Gr.26. –  Check selector mechanism for correct adjustment, and re-adjust if necessary → Chapter. –  If fitted, install tunnel brace → Rep. Gr.66. –  Check oil level in manual gearbox → Chapter. –  Follow the steps required after connecting the battery → Rep. Gr.27. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques ±15 %.

Securing gearbox to engine on vehicles with 1.8 ltr. turbocharged engine:

Item	Bolt	Nm
1	M12 x 67	65
2	M12 x 110 1)	65
3	M12 x 90	65
4	M10 x 50 2)	45
5	M10 x 45	45
6	M12 x 110 3)	65
A	Dowel sleeves for centralising
l  1) With bracket for wiring l  2) Special bolt with nut l  3) With nut

Securing gearbox to engine on vehicles with 4-cyl. TDI engine:

Item	Bolt	Nm
1	M12 x 75	65
2	M12 x 110 1)	65
3	M12 x 90	65
4	M10 x 50 2)	45
5	M10 x 45	45
6	M12 x 110 3)	65
A	Dowel sleeves for centralising
l  1) With bracket for wiring l  2) Special bolt with nut l  3) With nut

Securing gearbox to engine on vehicles with V6 TDI engine:

Item	Bolt	Nm
1	M12 x 80 1)	65
2	M12 x 90 2)	65
3	M12 x 80	65
4	M10 x 50 3)	45
5	M10 x 45	45
6, 7	M12 x 110	65
8	M12 x 67	65
A	Dowel sleeves for centralising
l  1) With brace for turbocharger l  2) With bracket for wiring l  3) Special bolt with nut

All models:

Component	Nm
Slave cylinder to gearbox	23 1)
Push rod to gearbox	40
Selector rod to gearbox	23
Connecting rod for selector rod to gearbox	23
Engine speed sender -G28- to gearbox	10
Gearbox mounting with bracket to gearbox	23
Heat shield for drive shaft to gearbox	23
Bracket for noise insulation to subframe	10
l  1) Renew bolt.