Audi Workshop Service and Repair Manuals

Installing gearbox 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. –  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 pipe/hose 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.

–  Screw in bottom engine/gearbox securing bolt -arrow A- and bolts for starter -arrow B-; at the same time 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-. –  Bolt tunnel cross member to body. First install bolts -2- and then bolts -3-. –  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. –  Bolt propshaft to gearbox → Rep. Gr.39. –  Align exhaust system so it is free of stress → Rep. Gr.26. –  Check gear oil level in gearbox → Chapter. –  Check selector mechanism setting and adjust if necessary → Chapter. –  After connecting battery, enter anti theft code for radio → Radio operating instructions. –  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

Engine/gearbox attachment (4-cylinder 1.9 ltr. turbo diesel 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 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 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
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
Propshaft to manual gearbox 1)		55
Heat shield for propshaft to cover for centre differential		25
Clamp for exhaust pipe		40
Bracket for noise insulation to subframe		10
l  1) Renew bolt