Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 2.7 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A- (Audi A4 Cabriolet only)

t	Rack -10 - 222 A /1- (Audi A4 Cabriolet only)

t	Adapter -10 - 222 A /3- (Audi A4 Cabriolet only)

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

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

t  Wing compensation plates -T40045- (Audi A4 Cabriolet only) t  Grease for clutch plate splines -G 000 100- t  Copper grease (commercially available) t  2 bolts (M10 x 20)   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-.

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

–  Loosen bolts/quick-release fasteners -1- and -2- and remove front noise insulation -A-. –  If fitted, loosen quick-release fasteners -3- and remove rear noise insulation -B-.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove left and right drive shaft noise insulation from wheel housing -arrows-.

–  Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts). –  Unbolt drive shafts -1- (left and right) from gearbox flange shafts.   Note Make sure you do not damage surface coating on drive shafts. –  Remove front exhaust pipe with particulate filter → Engine, mechanics; Rep. gr.26.

–  Unbolt bracket for exhaust pipe (left-side) on gearbox -arrows-.

Audi A4 Cabriolet: –  Remove bottom nuts -1- on engine mountings (left and right).   Note -Item 2- can be disregarded.

–  Carefully detach engine cover panel from the four retaining studs -arrows- one by one.

–  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.

–  Set up support bracket -10 - 222 A- with racks -10 - 222 A /1- and adapters -10-222 A /3-. –  Raise engine/gearbox assembly slightly at the front via the spindle.

Continued for all vehicles: –  Unbolt anti-roll bar mountings on left and right sides (-1- and -2-) and pivot anti-roll bar downwards.

–  Remove engine/gearbox bolts -6 ... 10- (accessible from below). Audi A4 Cabriolet: –  Lower engine/gearbox assembly again.

Continued for all vehicles: –  Unplug electrical connector -arrow- for engine speed sender -G28- and move electrical wire clear.

–  Remove nut -bottom arrow- and bolt -top arrow-, but do not remove starter.

–  Slacken nuts -arrows- at stop for torque reaction support. –  Press stop for torque reaction support upwards using a lever and tighten nuts again.   Note Adjusting the stop for torque reaction support prevents the engine from tilting at the front after the gearbox is removed.

–  Support gearbox with engine and gearbox jack -V.A.G 1383 A-.   Note The gearbox support -T10337- can also be used in place of the block of wood -1-.   WARNING Risk of injury The lock carrier must remain installed, and must not be moved to the service position.

–  First remove bolts -1- and then bolts -2- at tunnel cross member. –  Unscrew the two nuts -3- and detach tunnel cross member. –  Carefully lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Detach connector -arrow- for reversing light switch -F4- at right side of gearbox.

–  Unplug electrical connector -1- on exhaust gas pressure sensor 1 -G450- and move electrical wiring clear of gearbox. –  Remove bolts -arrows- and detach pressure lines.

–  Detach push rod -1-; to do so, unscrew hexagon socket head bolt. –  Unscrew connecting rod -2- for selector rod.

–  Unscrew nut -1- and pull gearbox selector lever -2- off gearbox selector shaft.

–  Detach clutch slave cylinder from gearbox -arrow- and secure with wire; do not open pipe/hose system.   Note Do not depress clutch pedal after removing slave cylinder.

–  If not already provided, drill a hole of 10.2 mm Ø -arrow- in the support elements of gearbox support -3282-.

–  Set up gearbox support -3282- for removing manual gearbox 0A2 with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The support elements-arrows- are shown on the adjustment plate in schematic form; the arrow on the adjustment plate points in the direction of travel. t  Adjustment plate can only be fitted in one correct position.

–  Align the adjustment plate parallel to the gearbox. –  Secure support elements to left side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on right side- to 20 Nm.

–  Secure support elements to right side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on left side- to 20 Nm.

–  Remove remaining engine/gearbox bolts -3 ... 5-. –  Press gearbox off dowel sleeves. –  Carefully lower gearbox, making sure there is sufficient clearance from drive shafts. –  Before carrying out assembly work, secure gearbox to assembly stand, using engine and gearbox support -VW 540- → Chapter.

–  If the removed gearbox is being renewed, the gearbox mounting -1- must be transferred to the replacement gearbox. Tightening torque for bolts -2- → Item.