Audi Workshop Service and Repair Manuals

Renewing gearbox cover (with gearbox installed)

Special tools and workshop equipment required

t	Drip tray -V.A.G 1306- or drip tray for workshop hoist-VAS 6208-

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

t	Universal dial gauge bracket -VW 387-

t	Thrust plate -VW 401-

t	Press tool -VW 407-

t	Tube -VW 420-

t	Multi-purpose tool -VW 771-

t	Assembly device -VW 792-

t	Thrust plate -3005-

t	Multi-point bit -3357-

t	-1-Internal puller -Kukko 21/1-

t	Dial gauge

t	Dial gauge extension

t	Depth gauge (accurate to within 5/100 mm or less)

t	Sealants -AMV 188 001 02-

Removing gearbox cover   WARNING t  Follow steps required when disconnecting battery → Rep. Gr.27. t  On vehicles with telematics: activate service mode of telematics control unit before disconnecting battery → Rep. Gr.91. –  Refer to coding on vehicles with encoded radio/radio navigation system (RNS); obtain coding if necessary.

–  With the ignition switched off, disconnect battery earth strap.   Note The gearbox cover can be renewed with the gearbox installed.

–  If fitted, loosen quick-release fasteners -2- and -3- and remove rear noise insulation -B-. –  Place drip tray -V.A.G 1306- or drip tray for workshop hoist-VAS 6208- under vehicle.

–  Use multi-point bit -3357- to remove oil drain plug -arrow- and allow gear oil to drain off completely. –  Screw oil drain plug back in and tighten to 25 Nm.

–  If fitted, remove bolts -arrows- and detach covers -1- and -2-.

–  Remove tunnel cross piece (front) -1--arrows-. Vehicles with 4-cylinder engine: –  Remove front exhaust pipe -3- in front of clamp -2- → Rep. Gr.26. Vehicles with 6-cylinder engine:

–  Separate exhaust system at clamps -arrows- and remove front exhaust pipe (right-side) with catalytic converter → Rep. Gr.26. Vehicles with 6-cylinder 3.0 ltr. engine: –  Remove Lambda probe in front of catalytic converter (left-side) at bottom → Rep. Gr.26. All models:

–  Remove heat shield -4- above exhaust system/catalytic converters.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (with gearbox support -T10337- attached). –  First remove bolts -3- and then bolts -2- at tunnel cross member -A-. –  Lower gearbox slightly. –  Remove both nuts -1- from gearbox mounting -B- and detach tunnel cross member -A-. –  Lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Remove selector rod -arrow A-. –  Unscrew hexagon socket head bolt on push rod -arrow B-.

If fitted, pull connector out of bracket -arrow-. –  Unplug connector -1- and move wiring -2- clear. –  Remove retainer for wiring -3-.

–  Unbolt gearbox support with gearbox mounting -arrows-. –  Place drip tray -V.A.G 1306- or drip tray for workshop hoist-VAS 6208- under vehicle.

–  Unscrew bolts -1- and -2- and remove gearbox cover.   Note Only bolts -2- used on gearboxes with magnesium housing are fitted with a washer.

–  If fitted, pull out securing bush for outer race for small tapered roller bearing. A -  Internal puller 12...14.5 mm, e.g. -Kukko 21/1-   Note The securing bush does not have to be reinstalled.

–  Screw adapter -VW 771/40- into pressure plate. –  Attach multi-purpose tool -VW 771- and pull outer race out via the pressure plate.

–  Remove circlip -1- and support plate -2-. –  Remove reverse gear wheel -3- and needle bearing and thrust washer located behind. –  Screw self-tapping screw -arrow- into centre of rubber disc -4- and pull out disc by means of self-tapping screw. Installing gearbox cover

Make sure the following components are fitted in the new gearbox cover: 1 -  Reverse gear shaft 2 -  Roller bearing 3 -  Oil collector 4 -  Bearing bush for ball sleeve –  Install reverse gear wheel with thrust washer, needle bearing, support plate and circlip → Chapter.

–  Also check that both plugs -arrows- are pressed into gearbox cover. Re-determining thickness of shim “S4”: –  Thoroughly clean sealing surface of housing and bearing seat on old and new gearbox covers.   Note t  Position of shim “S4” → Chapter. t  Use depth gauge (accurate to within 5/100 mm or less)

–  Measure difference in depth “a” on old and new gearbox cover. Example:

	Depth “a” (old gearbox cover)	257.40 mm
	Depth “a” (new gearbox cover)	257.56 mm
=	Difference	0.16 mm

–  If new gearbox cover is deeper, install a thicker “S4” shim. –  If previous gearbox cover is deeper, install a thinner “S4” shim. Example:

	Previous shim “S4”	0.69 mm
+	Difference	0.16 mm
=	New shim “S4”	0.85 mm

Shims available → .

–  Clean rubber disc -4- and pressure plate -3- and insert in gearbox cover. –  Install newly determined shim “S4”-2- and outer race for tapered roller bearing -1-.

–  Press outer race for tapered roller bearing into gearbox cover. –  Thoroughly clean sealing surface on gearbox housing.   Note Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing. –  Fit gearbox cover and tighten bolts to 22 Nm. Checking preload of tapered roller bearings for pinion shaft   Note Make sure that no gear is engaged when performing the next work step. –  Give both front wheels 11/2 turns in each direction so that tapered roller bearing settles.

–  Set up measuring tools and secure with bolt -arrow- to gearbox housing. –  Apply dial gauge (3 mm measuring range) onto centre of gearbox cover and set to “0” with 2 mm preload. –  Loosen all gearbox cover bolts approx. one turn. –  If the correct shims have been selected the dial gauge will now indicate the following value: l  0.05 ... 0.15 mm –  Detach measuring tools and gearbox cover. –  Clean sealing surface thoroughly for a second time and apply a thin coat of sealant -AMV 188 001 02-.   Note Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.

–  Fit gearbox cover and tighten bolts -1- and -2- to 22 Nm.   Note Only bolts -2- used on gearboxes with magnesium housing are fitted with a washer.

Fit oil seal as follows: –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of oil seal. –  Use tube -VW 420- to insert oil seal. l  Dimension -a- = 1 mm

–  Secure gearbox mounting -arrows-.

–  If fitted, attach retainer for wiring -3- and engage connector -1- and wiring -2-. –  Push selector rod on so that the securing bolt fits in the recess in the selector shaft.

–  Then secure selector rod -arrow A-. –  Then bolt push rod to gearbox -arrow B-.

–  Secure tunnel cross member -A- to gearbox mounting -B- with nuts -1-. –  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox far enough to be able to screw in the bolts -2-. –  First tighten bolts -2- and then bolts -3- to specified torque. –  Lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Install heat shield -4- above exhaust system/catalytic converters. –  Install front exhaust pipe -3- and/or catalytic converter → Rep. Gr.26. –  Align exhaust system so it is free of stress → Rep. Gr.26. –  Install tunnel cross piece (front) -1-. –  Check selector mechanism setting and adjust if necessary → Chapter. –  Fill up oil in gearbox and check oil level → Chapter. –  Install rear noise insulation (if fitted). –  Connect the battery.   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

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

Component		Nm
Oil drain plug		25
Gearbox cover to gearbox housing		22
Selector rod/selector joint to gearbox 1)		23
Push rod to gearbox		40
Tunnel cross piece (front) to body		55
Clamp for exhaust pipe		40
l  1) Renew bolt