Audi Workshop Service and Repair Manuals

Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine Installation is carried out in reverse sequence; note the following:   Note t  Renew self-locking nuts and bolts. t  Re-attach all cable ties at the same locations when re-installing.   WARNING t  Bolts and other components coming into direct contact with the gearbox housing have a surface coating that is designed to be compatible with either aluminium or magnesium → Chapter. t  In order to avoid contact corrosion, use only the bolts and other components listed in the → Electronic parts Catalogue. –  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 for clutch plate splines -G 000 100- to the splines. Do not grease guide sleeve. l  It should be possible to push the clutch plate back and forth slightly on the input shaft. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox. –  Ensure that intermediate plate is correctly positioned on engine (if fitted). –  Check clutch release bearing for wear and renew if necessary. –  Checking and servicing release bearing with glued plastic ring → Fig.. –  Checking release bearing with mechanically attached plastic ring → Fig.. –  Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Renew all self-locking nuts.

–  Using copper grease -Z 381 351 TE-, lightly lubricate surface where plunger makes contact with clutch release lever -arrow B-. –  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for hose/pipe assembly. –  Guide slave cylinder -1- into opening in gearbox housing, keeping it as straight as possible (without tilting plunger -arrow A-), and insert in recess -arrow B- on clutch release lever -3-.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-. –  Secure slave cylinder with new bolt -2-. –  When aligning the gearbox with the engine, turn crankshaft back and forth slightly to make it easier to insert the gearbox input shaft splines into the clutch plate.   Caution t  After installing the slave cylinder press the clutch pedal carefully. t  If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. t  The plunger of the slave cylinder is likely to have been guided past the clutch release lever. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. t  For comparison: normal pedal force is approx. 115 N.

–  Install bottom engine/gearbox securing bolt -arrow A- and bolt for starter-arrow B-; when doing this install starter → Rep. Gr.27. –  Lower engine and gearbox jack -V.A.G 1383 A- and move it aside. –  Tighten top bolts securing engine to gearbox to specified torque. Tightening torques →

–  Bolt tunnel cross member onto gearbox mounting -1-. –  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly. –  Bolt tunnel cross member to body. First install bolts -2- and then bolts -3-. Cabriolet:

–  Use support bracket -10 - 222 A- to lift engine just enough for nuts -3- to make contact with bottom surface of left and right console for engine mounting. All models:

–  Tighten the three bottom engine/gearbox securing bolts -arrows- to specified torque. Cabriolet: –  Lower engine to original position.

–  Tighten nuts -3- at right and left engine mounting. –  Secure anti-roll bar -2-. –  Secure torque reaction support to engine. All models: –  Push selector rod on so that the new securing bolt fits in the recess in the selector shaft.

–  Then secure selector rod -arrow A-. –  Then bolt push rod to gearbox -arrow B-. –  Bolt drive shafts to flange shafts → Rep. Gr.40. –  Install front exhaust pipe → Rep. Gr.26. –  Align exhaust system so it is free of stress → Rep. Gr.26. –  Check selector mechanism setting and adjust if necessary → Chapter. –  Check gear oil level in gearbox → Chapter. –  Connect the battery. –  Follow the steps required after connecting the battery → Rep. Gr.27.   Note t  When reconnecting battery, remember to activate vehicle equipment (radio/navigation system, clock, electric window) according to Owner's Manual. t  Deactivate telematics control unit service mode → Rep. Gr.91. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques ±15 %.

Engine/gearbox attachment (4-cylinder 1.6 ltr. and 2.0 ltr. engine)

Item	Bolt	Nm
1, 3, 4	M12×75	65
2,	M12×90	65
5, 6	M12×110	65
7…10	M10×45	45
11	M12×130 1)	65
A	Dowel sleeves for centralising
l  1) With nut

Engine/gearbox attachment (4-cylinder TDI engine and 1.8 ltr. petrol engine)

Item	Bolt	Nm
1, 3, 4	M12×67	65
2, 6	M12×90	65
5, 11	M12×110	65
7…10	M10×45	45
A	Dowel sleeves for centralising

Engine/gearbox attachment (6-cylinder 2.4 ltr. petrol engine)

Item	Bolt	Nm
1, 9, 10, 11	M10×45	45
2	M10×135	65
3	M12×130	65
4, 5, 6	M12×67	65
7	M12×90	65
8	M12×80	65
A	Dowel sleeves for centralising

Engine/gearbox attachment (6-cylinder 3.0 ltr. petrol engine)

Item	Bolt	Nm
1, 9, 10, 11	M10×60	45
2	M10×150	65
3	M12×130	65
4	M12×80	65
5, 6, 8	M12×90	65
7	M10×100	45
A	Dowel sleeves for centralising

Gearbox support with gearbox mounting to gearbox

Bolts -arrows-

23 Nm

Tunnel cross member to gearbox mounting and body

Component		Nm
-1- Tunnel cross member to gearbox mounting		23
-2- Tunnel cross member to body 1)		110 Nm + 90° 2)
-3- Tunnel cross member to body 1)	M10	55
l  1) Always renew bolt with washer l  2) 90° is equivalent to a quarter turn

Anti-roll bar -2- and engine mounting to console for engine mounting

Component		Nm
-1- Anti-roll bar to console for engine mounting 1)		25
-3- Engine mounting to console for engine mounting		25
l  1) Renew nuts

Component		Nm
Torque reaction support to engine	M8 M10	25 40
Torque reaction stop to engine 4-cylinder TDI		28
Engine speed sender -G28-		10
Slave cylinder to gearbox1)		23
Heat shields above drive shafts to gearbox		23
Selector rod/selector joint to gearbox 1)		23
Push rod to gearbox		40
Tunnel cross member to body		55
Clamp for exhaust pipe		40
Bracket for noise insulation to subframe		10
l  1) Renew bolt