Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 4-cyl. petrol engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/43-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

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

t  Counterhold tool -T10172- with adapter -T10172/5-

t  Wing compensation plate -T40045- t  Grease for clutch plate splines -G 000 100- t  Copper grease -Z 381 351 TE- Procedure   Note t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. t  Heat insulation sleeves removed during removal of gearbox must be fitted in the same position when installing.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, disconnect battery earth strap -arrow-.

–  Remove engine cover panel -arrows-.

–  Detach rubber seal from edges of wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

–  Set up support bracket -10-222 A- with adapters -10-222/3- on wing mounting flanges. –  Engage spindles on engine lifting eyes as illustrated. –  Take up weight of engine using spindles.

–  On vehicles fitted with auxiliary heater, remove screws -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Release bolts or quick-release fasteners -arrows- and detach noise insulation panel.

–  Detach bracket -arrow- for noise insulation.

–  Unbolt heat shield -arrow- for drive shaft (right side) from gearbox. –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Unscrew bolts -1 ... 4- and remove front cross piece, if fitted.   Note

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Separate the exhaust system at the clamp -arrow- and slide the clamp to rear.

–  Unbolt front exhaust pipe from catalytic converter -arrows-. –  Remove bolt -1- and detach front exhaust pipe.

–  If fitted, unbolt heat shield for propshaft -arrows-.

–  Remove bolts -arrows- at gearbox/propshaft flange.

–  To do this, use counterhold tool -T10172- with adapter -T10172/5-

–  Push propshaft -1- together towards rear final drive. The constant velocity joints can be moved axially. –  Use wire -arrow- to tie propshaft -1- onto heat shield.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -arrow- between lifting column and gearbox) and support gearbox.

–  First remove bolts -1- and then bolts -2- at rear cross member. –  Unscrew two nuts -3- and detach rear cross member.

–  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

–  Unscrew bottom engine/gearbox securing bolts -arrows-. –  Lower gearbox with engine and gearbox jack -V.A.G 1383 A-.

–  If fitted, unplug electrical connector -arrow- for speedometer sender -G22- on left of gearbox.

–  If fitted, remove engine speed sender -G28- from left side of gearbox -arrow- and lay aside.

–  Unscrew nut -1- and detach selector shaft lever -2- from selector shaft.

–  Unplug electrical connector -arrow- for reversing light switch -F4- and move electrical wire clear.

–  Unscrew connecting rod -2- for selector rod. –  Unscrew push rod -1- by using an 8 mm hexagon key when unscrewing bolt.

–  Remove upper engine/gearbox securing bolts -arrows 1- and -arrows 2-. Please note that there may be brackets for wires/lines or similar located beneath the bolts (important for installation).

–  Unbolt starter -1--arrows- and secure starter in engine compartment.   Note Starter cables do not have to be disconnected.   Note

t  The positions of the support elements are shown on the adjustment plate -3282/12- in schematic form -A- (the arrow -B- points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support -3282- to coincide with holes in adjustment plate -3282/12-. –  Screw in support elements -A- as shown on adjustment plate.

–  Place engine and gearbox jack -V.A.G 1383 A- with gearbox support -3282- underneath gearbox and secure to left side ...

–  ... and to right side of gearbox. –  Remove the remaining engine/gearbox securing bolts. –  Press gearbox off dowel sleeves and lower carefully with engine and gearbox jack -V.A.G 1383 A- just far enough to gain access to the clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic line to clutch slave cylinder is not damaged.

–  Detach clutch slave cylinder from gearbox -arrow- and secure with wire; do not open pipe/hose system.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely with engine and gearbox jack -V.A.G 1383 A-.   Note t  Make sure that all wiring has been detached from top of gearbox. t  When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being renewed, the gearbox mounting -1- must be transferred to the replacement gearbox -bolts 2-.