Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 2.5 ltr. TDI engine Installation is carried out in reverse sequence; note the following: –  Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Always renew self-locking bolts and nuts. –  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 clutch release bearing for wear and renew if necessary → Item. –  If plastic ring -arrows- has come loose, service release bearing as required → Fig..   Note The release bearing must be renewed if the groove worn on the plastic ring is deeper than 0.8 mm. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  If fitted, place intermediate plate on dowel sleeves at engine flange. –  Before installing gearbox, tie electrical wires and brackets off to one side so that they are not trapped between the engine and the gearbox.

–  Place gearbox on engine and gearbox jack. –  Align adjustment plate and gearbox parallel to one another. –  Attach support elements-arrows- on right side of gearbox.

–  Attach support elements-arrow A- and -arrow B- on left side of gearbox.

–  Before installing gearbox, check that brace -B- is still moved to one side -direction of arrow-.

–  Lightly lubricate surface where plunger and clutch release lever make contact -arrow B- using copper grease (commercially available). –  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 clutch slave cylinder with new bolt -arrow-. Tightening torque → Item   Caution t  Press the clutch pedal carefully after installing the gearbox. 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. –  Insert gearbox, making sure there is sufficient clearance to drive shafts. –  When aligning the gearbox with the engine, turn crankshaft back and forth slightly to make inserting the gearbox input shaft splines into the clutch plate easier.

–  Insert connecting bolts at top and side of engine/gearbox assembly -arrows- and tighten. Secure bracket -3- at the same time. –  Tighten bolt -1- on top brace for turbocharger to 22 Nm.

–  Install gearbox selector lever and tighten nut -arrow-. Tightening torque → Item

–  Install push rod -1-; to do so, tighten hexagon socket head bolt. Tightening torque → Item –  Secure connecting rod -2- for selector rod. Tightening torque → Item

–  Raise gearbox using engine and gearbox jack -V.A.G 1383 A- and secure tunnel cross member to body (finger-tight), using new bolts -2- and -3-. –  Bolt tunnel cross member onto gearbox mounting -4-. Tightening torque → Item –  Bolt drive shafts to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.

Audi Cabriolet: –  First remove front bolts -2- and -3- on subframe (left and right). Then remove bolts -1-. –  Lower subframe at the front.

–  Tighten the three lower engine/gearbox securing bolts at bottom -arrows- to torque setting.

–  Renew front subframe bolts -1 ... 3- on both sides of the vehicle. Tighten bolts hand-tight only.

Before tightening the subframe mountings, the subframe must be aligned with the body using locating pins -3393-. l  Hole -1-, hole -2- in subframe and hole -3- in aluminium bracket must be in alignment on both sides.   Note This alignment can only replace a subsequent wheel alignment check if holes -1- and -2- coincided before the repair work was carried out. –  Secure subframe mountings → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.

–  Tighten nuts -1- for engine mountings → Engine, mechanics; Rep. gr.10.   Note -Item 2- can be disregarded.

Continued for all vehicles: –  Tighten bolts -1 … 3- for tunnel cross member. Tightening torques → Chapter

–  Tighten the three lower engine/gearbox securing bolts at bottom -arrows- to torque setting. The remaining installation steps are carried out in the reverse sequence; note the following points: –  Install starter → Electrical system; Rep. gr.27. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. gr.26. –  Check selector mechanism setting and adjust if necessary → Chapter. –  Follow steps required after connecting battery → Electrical system; Rep. gr.27.   Caution Never use a charger to aid starting. Otherwise, the vehicle's control units could be damaged. –  If necessary, check wheel alignment → Running gear, front-wheel drive and four-wheel drive; Rep. gr.44. t  A wheel alignment check is not necessary if the alignment of the subframe in relation to the body was checked using locating pins -3393- prior to dismantling and assembly of the subframe (before tightening bolts). t  A wheel alignment check must, however, be carried out if the alignment of the subframe relative to the body was not checked or if it was not possible to fully insert the two locating pins -3393- into the holes. –  Check gear oil level in gearbox → Chapter. 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 gear oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques is ± 15%.

Gearbox to engine

Item	Bolt	Nm
1	M12 x 67	65
2 (1	M12 x 75	65
3 2)	M12 x 90	65
4	M12 x 75	65
5 3)	M10 x 50	45
6, 7, 8	M10 x 45	45
9, 10 4)	M12 x 110	65
11	M12 x 67	65
A	Dowel sleeves for centralising
1) With strut for turbocharger 2) With bracket for wiring 3) Hammer head bolt with nut 4) Starter to gearbox

Component	Nm
Heat shield for drive shaft to gearbox	23
Engine mounting to engine support	23
Bracket for noise insulation to subframe	10