Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 2.5 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Adapters -10 - 222 A /3-

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

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

t  Wing compensation plate -T40045- t  Grease for clutch plate splines -G 000 100- t  Copper grease (commercially available) t  2 bolts (M10 x 20) 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-.

–  Lift off engine cover -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.

–  Assemble support bracket -10-222A- together with racks -10-222A/1- and adapters -10-222 A/3-. –  Partly take up weight of engine/gearbox assembly with the spindles.

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

–  Loosen bolts/quick-release fasteners -1- and -2- and remove front noise insulation -A-. –  If fitted, loosen quick-release fasteners -3- and remove rear noise insulation -B-.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove left and right drive shaft noise insulation from wheel housing -arrows-.

–  Unbolt heat shield for drive shaft (left-side) -arrows- (3 bolts). –  Unbolt drive shaft -1- from flange shaft (left and right) and move clear to the front, taking care not to damage protective coating. –  Remove front exhaust pipe with catalytic converter → Engine, mechanics; Rep. gr.26.

Audi Cabriolet: –  Unscrew nuts -1- at bottom of engine mountings (left and right).

–  If fitted, unclip operating rod for vehicle level sender -G78- from lower transverse link -arrow-.

–  Before loosening the subframe, use locating pins -3393- to check whether holes -1- and -2- are aligned. If this is not the case, wheel alignment has to be checked after installing the subframe.

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

–  Unscrew the three bottom bolts connecting the engine to the gearbox from the engine side -arrows-.

–  Temporarily secure subframe again. Temporary tightening torque: 1 -  approx. 100 Nm 2 -  approx. 70 Nm 3 -  approx. 70 Nm   WARNING Do not renew bolts yet or tighten to their final torque. This will be done when installing the gearbox.

Continued for all vehicles: –  Unscrew bottom engine/gearbox securing bolts -arrows-.

–  Unplug electrical connector -arrow- for engine speed sender -G28- and move electrical wire clear.

–  Support gearbox with engine and gearbox jack -V.A.G 1383 A-.   Note The gearbox support -T10337- can also be used in place of the block of wood -1-.

–  First remove bolts -1- and then bolts -2- at tunnel cross member. –  Unscrew the two nuts -3- and detach tunnel cross member. –  Carefully lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Detach connector -arrow- for reversing light switch -F4- at right side of gearbox.

–  Detach push rod -1-; to do so, unscrew hexagon socket head bolt. –  Unscrew connecting rod -2- for selector rod.

–  Unscrew nut -1- and pull gearbox selector lever -2- off gearbox selector shaft.

–  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.

–  Unscrew top engine/gearbox securing bolts -arrows-. While doing so, note location of bracket -3- (important when installing). –  Move bracket -3- with wiring clear to the side and secure with wire if necessary. –  Unscrew securing bolt -1- (on rear of turbocharger) one turn, pivot strut -2- in direction of -arrow- and then tighten bolt -1- again lightly.

–  If not already provided, drill a hole of 10.2 mm Ø -arrow- in the support elements of gearbox support -3282-.

–  Set up gearbox support -3282- for removing manual gearbox 0A2 with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The support elements-arrows- are shown on the adjustment plate in schematic form; the arrow on the adjustment plate points in the direction of travel. t  Adjustment plate can only be fitted in one correct position.

–  Align the adjustment plate parallel to the gearbox. –  Secure support elements to left side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on right side- to 20 Nm.

–  Secure support elements to right side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on left side- to 20 Nm.

–  Unbolt starter -1- from engine/gearbox -arrows- and secure as necessary → Electrical system; Rep. gr.27.   Note Starter cables do not have to be disconnected.

–  Remove remaining engine/gearbox connecting bolt -arrow A-. –  Press gearbox off dowel sleeves. –  Carefully lower gearbox, making sure there is sufficient clearance from drive shafts. –  Before carrying out assembly work, secure gearbox to assembly stand, using engine and gearbox support -VW 540- → Chapter.

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