Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 4-cylinder 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 All cable ties which are released or cut open during removal 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 off engine cover panel -arrows-.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move coolant expansion tank (with coolant hoses -1 … 3- attached) clear to one side.

–  Move clear electrical wiring at fuel filter bracket. –  Unscrew nuts -arrows- and move fuel filter aside (with fuel hoses attached).

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

–  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.

–  Position support bracket -10-222 A- on wing mounting flange with adapters -10-222A/3-. –  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.

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

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

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

–  If fitted, remove engine speed sender -G28- on left side of gearbox.

–  Unscrew temperature sender after particulate filter -G527--item 1-. –  Unscrew nuts -arrows- and remove front exhaust pipe behind particulate filter → Rep. Gr.26.

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

–  Unscrew the three lower engine/gearbox securing bolts -arrow-.

–  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.

–  Re-tension front spindle -10 - 222 A /11- slightly (do not lift engine while doing so).

–  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.

–  Remove remaining engine/gearbox securing bolts -arrow A- and -arrow B-.

–  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. –  If fitted, move clear electrical wiring at top of gearbox. –  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-.