Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary items required:

• ◆ Gearbox support 3282
• ◆ Adjustment plate 3282/12
• ◆ Gearbox jack V.A.G 1383 A

Removing

• ‒ Obtain radio code on vehicles with coded radio.

• ‒ With ignition switched off disconnect battery earth strap.

Note:

For better access to the bolts securing the engine to the gearbox, remove the exhaust pipe and catalytic converter first.

• ‒ → Unbolt noise insulation cover above cylinder head cover -arrows-.

• ‒ → Remove heat shield above turbocharger -arrows-.

• ‒ → Unbolt exhaust pipe from turbocharger manifold -arrows-.

• ‒ → Remove noise insulation (two sections, -arrows A ... C-).
• ‒ Unbolt mounting for noise insulation.

• ‒ Unscrew bolts -arrows- for bracket -A-.

• ‒ → Remove support -1-.
• ‒ Loosen clamp on exhaust pipe -arrows on left- and take out exhaust pipe together with catalytic converter.

• ‒ Remove engine/gearbox securing bolts which are accessible from above.
• ‒ → Slacken bolt -A- (on rear of turbocharger) by a few turns and pivot strut -B- to one side in direction of arrow. Then tighten bolt -A- again slightly.

Note:

The illustration shows the engine from the rear with the gearbox removed.

• ‒ → Slacken bolt -2- on noise insulation cover above left-hand drive shaft.
• ‒ Disengage retainer -1- and remove noise insulation cover.

• ‒ → Remove heat shield for left-hand inner joint -1- from gearbox
  -arrows-.
• ‒ Unbolt drive shafts -1- from gearbox (left and right sides), lift clear and tie in position.

• ‒ → Remove engine speed sender -G28 from left-hand side of gearbox -arrow- and place to one side.
• ‒ Pull connector off sender for speedometer.
• ‒ Pull off connector on reversing light switch.
• ‒ Unclip wiring for speed sender and reversing light switch on gearbox.
• ‒ Unscrew bolts securing starter.
• ‒ Pull starter out slightly, but leave starter cables connected.
• ‒ Remove all but one of the engine/gearbox securing bolts from below (one bolt is left in place to hold the engine and gearbox together).

• ‒ → Unscrew and remove bolts -1- and -2- on right and left and remove support -A-.

• ‒ → Lower subframe at rear and place spacer (e.g. wedge of wood) in gap.

• ◆ -a- = max. 50 mm

• ‒ → Unbolt connecting rod -2- for selector rod on right-hand side of gearbox.
• ‒ Remove hexagon socket head bolt from push rod -1-.

• ‒ → Unscrew nut -1- and pull selector rod lever -2- off gearbox selector shaft.

• ‒ → Set up gearbox support 3282 with adjustment plate 3282/12 for removal of manual gearbox 01E (front-wheel drive) and place on gearbox jack V.A.G 1383 A.

•     A -    Attachments

Notes:

• ◆ → The positions for the attachments are indicated by symbols (-A-). Arrow -B- points in the direction of travel.
• ◆ Adjustment plate 3282/12 can only be fitted in one position.
• ◆ The elongated holes in adjustment plate 3282/12 allow for different versions of the gearbox housing and gearbox cover.

• ‒ → Run gearbox jack V.A.G 1383 A with gearbox support 3282 in under the gearbox and take up the weight of the gearbox.
• ‒ Secure gearbox to gearbox support 3282.

Note:

If gearbox support 3282 is not available, the gearbox can be removed and installed using gearbox jack V.A.G 1383 A.

• ‒ → Support gearbox with gearbox jack V.A.G 1383 A.

• ‒ → Unscrew bolts -1- and -2- and remove right and left gearbox supports from gearbox and subframe together with bonded rubber mountings.
• ‒ Remove the last remaining engine/gearbox securing bolt.

• ‒ Press gearbox off dowel sleeves and lower carefully with gearbox jack V.A.G 1383 A just far enough for access to the slave cylinder.

Note:

When lowering gearbox ensure hydraulic pipe/hose to slave cylinder is not damaged.

• ‒ → Remove bolt -arrow- and take out slave cylinder from the rear. Do not open the pipe/hose system.

Note:

Do not depress clutch pedal after removing slave cylinder.

• ‒ Lower gearbox completely.

Note:

When lowering gearbox ensure there is sufficient clearance to drive shafts.

Installing

Installation is carried out in the reverse order, when doing this note the following:

• ‒ Renew all seals and gaskets.
• ‒ Renew all self-locking nuts.
• ‒ Check whether dowel sleeves for aligning gearbox with engine are in the gearbox flange. Insert if necessary .
• ‒ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Do not grease guide sleeve.
• ‒ Check clutch release bearing for wear and renew if necessary.
• ‒ Coat contact surface for clutch slave cylinder push rod with a thin layer of copper grease, e.g. Z381 351 TE.

• ‒ → Before installing gearbox, check whether strut -B- is still pivoted to one side (in direction of arrow).
• ‒ Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox.

• ‒ → Lift gearbox until clutch slave cylinder with bracket for pipe/hose can be installed (arrow).
• ‒ Align exhaust system free of stress

=> 6-cylinder diesel direct injection engine (TDI), Mechanics; Repair group 26; Removing and installing parts of the exhaust system; Aligning exhaust system free of stress

• ‒ Check adjustment of selector rod and push rod; readjust if necessary => Page 34-16.
• ‒ Check oil level in gearbox => Page 34-39.

• ‒ After connecting battery, enter anti-theft code for radio

=> Radio operating instructions

• ‒ Close windows fully using electric window switches.
• ‒ Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
• ‒ Set clock to correct time.

Tightening torques

• ‒ → Engine/gearbox securing points (illustration shows gearbox flange)

Dowel sleeves -A- for aligning.

    1)    Special bolt

→ Subframe to body

    1)    Always replace bolts

    2)    Different torques=>Fig.1

Fig.1    Note different torques

New bolts with a grooved base will be used on vehicles from model year 1998 onwards. These bolts can also be used for older models.

• ‒ Bolt A - plain base (see arrow)
  Tightening torque: 25 Nm
• ‒ Bolt B - grooved base (see arrow)
  Tightening torque: 75 Nm