Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 2.5 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Rack -10-222 A /1-

t	Adapter -10-222 A /3-

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

t	Mounts -3282/49- (2x)

t	Mounts -3282/52- (2x)

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

t  Wing compensation plate -T40045- t  Drill Ø 10.2 mm t  Bolt M10x20 (2x) t  Grease for clutch plate splines -G 000 100- t  Copper grease -Z 381 351 TE- Removing   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-.

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

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical wiring leading to coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank clear to one side (with coolant hoses -1- and -2- attached).

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  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 adapters -10-222/3- on wing mounting flanges. –  Take up weight of engine using spindles.

–  Remove front left wheel. –  Remove noise insulation -1- in wheel housing (left-side).

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

–  Release fasteners -1 ... 3- and detach front and rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove heat shield -arrows- for drive shaft (left-side). –  Unbolt drive shafts -1- (left and right) from gearbox flange shafts.   Note Make sure you do not damage surface coating on drive shafts.

–  Remove nuts -arrows-.

–  Remove bolt -1-.

–  Release clamp(s) -arrow- and remove front exhaust pipe.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

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

–  Slacken nuts -arrows- at stop for torque reaction support, but do not remove.

–  Unbolt anti-roll bar mountings on left and right sides (-1- and -2-) and pivot anti-roll bar downwards.

–  Unscrew nuts -1- on left and right engine mountings until bottom of nuts is flush with end of studs. –  Use support bracket -10-222 A- to lift engine just enough for nuts -1- to make contact with bottom surface of left and right consoles.

–  Unscrew bottom engine/gearbox securing bolts -arrows-. –  Lower engine back down. Keep spindles under tension.

–  Unbolt heat shield for propshaft -arrows-.

–  Remove bolts -arrows- at gearbox/propshaft flange. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie up propshaft to side.

–  Unplug electrical connector -arrow- for reversing light switch -F4- on right side of gearbox and move electrical wire clear.

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

–  Drill a hole of 10.2 mm Ø -arrow- in supporting element of gearbox support -3282-.

–  To remove manual gearbox 0A3, four-wheel drive, set up gearbox support -3282- with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The positions of the support elements -arrows- are shown on the adjustment plate in schematic form (the arrow points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Align the adjustment plate parallel to the gearbox. –  Secure the supporting elements to the left side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on right side- to 20 Nm.

–  Secure the supporting elements to the right side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on left side- to 20 Nm.

–  First remove bolts -1- and then bolts -2- at tunnel cross member.

–  Unscrew nuts -arrows- and detach tunnel cross member.

–  Slowly lower rear of gearbox with engine and gearbox jack -V.A.G 1383 A-.   Note Do not lower the gearbox too far: the distance between the subframe and the body (dimension -a-) must not be more than 60 mm.

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

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

–  Unscrew top engine/gearbox securing bolts -arrows-. While doing so, note location of bracket -3- (important when installing). –  Move bracket for wiring -3- clear to the side and secure with wire if necessary. –  Loosen securing bolt -1- (at rear of turbocharger) one turn and pivot brace -2- to one side in direction of arrow. Then tighten bolt -1- slightly. –  Remove remaining engine/gearbox bolts.

–  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.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If you will be installing a new gearbox instead of the one removed, the gearbox mounting has to be transferred to the new gearbox -arrows-.