Audi Workshop Service and Repair Manuals

Removing and installing end cover   Note t  Rules for cleanliness when working on the automatic gearbox → Chapter. t  General repair instructions → Chapter. Special tools and workshop equipment required

t  Multi-point bit -3357-

t  Engine and gearbox jack -V.A.G 1383 A- t  Block of wood Removing   WARNING t  The lock carrier must remain installed throughout the procedure, and must not be moved to the service position. t  This is the only way to ensure that the engine/gearbox assembly does not drop out towards the rear when the tunnel cross member is released. t  The torque reaction support on the lock carrier takes up the weight of the assembly.

–  Remove rear noise insulation (loosen fasteners -2- and -3-). –  Remove front exhaust pipe → Rep. Gr.26. –  Drain off ATF → Chapter.

–  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 -V.A.G 1383 A- to lift gearbox up slightly.   WARNING Risk of injury The lock carrier must remain installed, and must not be moved to the service position.

–  First unscrew bolts -1- and -2-, then bolts -3- and -4-. –  Slowly lower tunnel cross member with engine and gearbox jack -V.A.G 1383 A-.

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

–  Release electrical connector -1- and detach from gearbox.   Note -Arrows- can be disregarded.

–  Remove bolts -2- and detach bracket -3- for selector lever cable from gearbox.

–  Use removal lever -80 - 200- to prise selector lever cable -A- off selector shaft lever -arrow-.   Note Do not bend or kink the selector lever cable.

–  Remove bolts -2- and take off gearbox support -1- together with gearbox mounting.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove bolts -arrows- and take off end cover.

Installing l  Tightening torque → Chapter Installation is carried out in reverse sequence; note the following:   Note Renew seals/gaskets and bolts for end cover. –  Slide new seal -A- onto connector of automatic gearbox control unit -J217-, with twin lips facing outwards.   Note -Arrows- can be disregarded. –  Clean sealing surfaces on gearbox housing and end cover. –  If any dowel sleeves were removed from gearbox housing or cover, these must be re-fitted in same places.

–  Place new gasket for end cover -A- onto gearbox housing.   Note t  The gasket can be either metal or paper. The new gasket must be made of the same material as the old one → Parts catalogue. t  Make sure dowel sleeves are correctly seated.

–  Fit end cover and make sure that gasket does not move out of position. –  Screw in new bolts -arrows- in diagonal sequence until hand-tight and then tighten to specified torque. –  Check installation position of seal -A-: l  Seal must be flush fitted (the sealing lips must not be kinked).

–  Tighten bolts -2- for bracket -3- for selector lever cable.   Note t  Do not bend or kink the selector lever cable. t  Before installing, lightly grease cable eye and ball socket on selector lever cable with polycarbamide grease -G 052 142 A2-.

–  Press selector shaft lever -A- at gearbox to rear as far as it will go -arrow- until parking lock engages.

–  Check whether selector lever is in position “P” and carefully press socket end of selector lever cable -2- onto selector shaft lever.   Note t  Take care not to bend selector shaft lever when pressing on cable; support lever if necessary, as otherwise selector mechanism can no longer be adjusted accurately. t  -Item 1- can be disregarded. –  Install gearbox support with gearbox mounting → Chapter. –  Install tunnel cross member → Rep. Gr.40. –  Install front exhaust pipe → Rep. Gr.26. –  Adjust selector lever cable → Chapter. –  Fill up with ATF → Chapter. Tightening torque

Component	Nm
End cover to gearbox	15 + 90° 1)2)
l  1) Renew bolts. l  2) Tighten in diagonal sequence.