Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 4-cyl. TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/43-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

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

t  Wing compensation plate -T40045- t  Grease for clutch plate splines -G 000 100- t  Copper grease -Z 381 351 TE- Procedure   Note t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. t  Heat insulation sleeves removed during removal of gearbox must be fitted in the same position when installing.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, disconnect battery earth strap -arrow-.

–  Pull dipstick -1- out of guide tube. –  Unclip caps -arrows-. –  Unscrew nuts -arrows- and detach engine cover. –  Remove insulation from beneath cover. –  Re-insert dipstick in guide tube.

–  Detach rubber seal from edges of wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

–  Release retaining clip -A- and loosen clip -B- to detach air intake hose -arrow-.

–  Set up support bracket -10-222 A- with adapters -10-222/3- on wing mounting flanges. –  Engage spindles on engine lifting eyes as illustrated. –  Take up weight of engine using spindles.

–  On vehicles fitted with auxiliary heater, remove screws -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Release quick-release fasteners -1 ... 3- and detach noise insulation panels (front -A- and rear -B-).

–  Detach bracket -arrow- for noise insulation.

–  Remove noise insulation -1- in wheel housing (left and right).

–  Unbolt heat shield -arrow- for drive shaft (right side) from gearbox. –  Unbolt drive shafts (left and right) from gearbox flange shafts.   Note

The flexible joint (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Disconnect exhaust system at clamp -arrow-.

–  Detach front exhaust pipe -1- behind catalytic converter -arrows-. –  Remove heat shield -2-.

–  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) and support gearbox.

–  First remove bolts -1- and then bolts -2- at tunnel cross member. –  Unscrew two nuts -3- and detach tunnel cross member.

–  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly. –  Unscrew the 3 bottom engine/gearbox securing bolts -arrows-. –  Lower gearbox with engine and gearbox jack -V.A.G 1383 A-.

–  Detach starter from engine/gearbox and secure if necessary → Electrical system; Rep. Gr.27.   Note Starter cables do not have to be disconnected.

–  Unplug electrical connector -arrow- for reversing light switch -F4- and move electrical wire clear.

–  If fitted, unplug electrical connector -arrow- for speedometer sender -G22- on left of gearbox.

–  Unscrew connecting rod -2- for selector rod. –  Unscrew push rod -1- by using an 8 mm hexagon key when unscrewing bolt.

–  Unscrew nut -1- and detach selector shaft lever -2- from selector shaft.

–  Remove upper engine/gearbox securing bolts -arrows 1- and -arrows 2-. Please note that there may be brackets for wires/lines or similar located beneath the bolts (important for installation).

–  To remove manual gearbox 01E (front-wheel drive) set up gearbox support -3282- with adjustment plate -3282/12- and place on engine and gearbox jack -V.A.G 1383 A-. –  Fit support elements -A-.   Note

t  The positions of the support elements are shown on the adjustment plate -3282/12- in schematic form -A- (the arrow -B- points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Place engine and gearbox jack -1383 A- with gearbox support -3282- underneath gearbox and position adjustment plate so it is parallel with gearbox. –  Fit support elements to right side of gearbox and rear of gearbox.

–  Secure support element to left side -arrow- of gearbox. –  Remove the remaining bolts connecting the engine to the gearbox. –  Press gearbox off dowel sleeves and lower carefully with engine and gearbox jack -V.A.G 1383 A- just far enough to gain access to the clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic line to clutch slave cylinder is not damaged.

–  Detach clutch slave cylinder from gearbox -arrow- and secure with wire; do not open pipe/hose system.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely with engine and gearbox jack -V.A.G 1383 A-.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being renewed, the gearbox mounting -arrows- must be transferred to the replacement gearbox. Installing gearbox → Chapter.