Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 3.0 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Rack -10-222 A /1-

t	Adapter -10-222 A /3-

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

t	Mounts -3282/49- (2x)

t	Mounts -3282/52- (2x)

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

t  Wing compensation plate -T40045- t  Drill Ø 10.2 mm t  Bolt M10x20 (2x) t  Copper grease -Z 381 351 TE- t  Grease for clutch plate splines -G 000 100- Removing l  Lock carrier and torque reaction support installed.   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-.

–  Carefully detach engine cover panel from the four retaining studs -arrows- one by one.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical wiring leading to coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank clear to one side (with coolant hoses -1- and -2- attached).

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Remove engine/gearbox securing bolts -4- and -5-.

–  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. –  Take up weight of engine using spindles. –  Remove front left wheel.

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

–  Open quick-release fasteners -1 ... 3- and detach noise insulation (front and rear).

–  Unbolt bracket for noise insulation -arrows-.

–  Remove noise insulation -1- in wheel housing (left-side).

–  Remove heat shield -arrows- for drive shaft (left-side). –  Unbolt drive shafts -1- (left and right) from gearbox flange shafts.   Note Make sure you do not damage surface coating on drive shafts.

–  Disconnect exhaust system at clamp -arrow-.

–  Remove bolt -arrow- at bracket for front exhaust pipe.   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.

–  Unscrew nuts -arrows- and remove front exhaust pipe with main catalytic converter.

–  Unbolt bracket for front exhaust pipe (left-side) on gearbox -arrows-.

–  Unbolt heat shield for propshaft -arrows-.

–  Remove bolts -arrows- at gearbox/propshaft flange. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie up propshaft to side.

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

–  Unplug electrical connector -arrow- for reversing light switch -F4-.

–  Unscrew bolt -1- and nut -4- and remove starter.   Note The electrical wires -2- and -3- remain connected

–  Unbolt anti-roll bar mountings on left and right sides (-1- and -2-) and pivot anti-roll bar downwards.

–  Remove engine/gearbox securing bolts -6 ... 10-.   Note Bolt -3- should remain screwed in hand-tight.

–  Slacken nuts -arrows- at stop for torque reaction support. –  Press stop for torque reaction support upwards using a lever and tighten nuts again.   Note Adjusting the stop for torque reaction support prevents the engine from tilting at the front after the gearbox is removed.   WARNING Make sure that the lock carrier remains installed during the following work steps and is not in the service position.

–  Drill a hole of 10.2 mm Ø -arrow- in supporting element of gearbox support -3282-.

–  To remove manual gearbox 0A3, four-wheel drive, set up gearbox support -3282- with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The positions of the support elements -arrows- are shown on the adjustment plate in schematic form (the arrow points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Align the adjustment plate parallel to the gearbox. –  Secure the supporting elements to the left side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on right side- to 20 Nm.

–  Secure the supporting elements to the right side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on left side- to 20 Nm.

–  First remove bolts -1- and then bolts -2- at tunnel cross member.

–  Unscrew two nuts -arrows- and detach tunnel cross member.

–  Slowly lower gearbox with engine and gearbox jack -V.A.G 1383 A-.   Note Do not lower the gearbox too far: the distance between the subframe and the body (dimension -a-) must not be more than 60 mm.

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

–  Unscrew nut -1- and pull gearbox selector lever -2- off gearbox selector shaft. –  Remove the last engine/gearbox securing bolt.

–  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.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If you will be installing a new gearbox instead of the one removed, the gearbox mounting has to be transferred to the new gearbox -arrows-.