Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 2.0 ltr. normally aspirated engine (also for Audi Cabriolet)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Removal lever -80-200-

t	Gearbox support -3282-

t	Adjustment plate -3282/30-

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

t  Wing compensation plate -T40045- Procedure –  Shift selector lever to position “P”.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  Slide battery cover towards right side of vehicle -arrow 1- and lift off -arrow 2-.

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

–  Pull off engine cover panel -arrows-.

–  Remove air intake hose between air mass meter and intake connecting pipe -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- on wing mounting flanges (spindle faces to rear). –  Uncover rear lifting eye on engine. –  Engage hook of spindle in rear lifting eye on engine. –  Take up weight of engine with spindle of support bracket, but do not lift.

–  Remove both front wheels. –  On vehicles fitted with auxiliary heater, remove bolts -arrows- securing exhaust pipe of auxiliary heater to noise insulation.

–  Loosen bolts/quick-release fasteners -1 ... 3- and detach front and rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove inner covers on vehicle underside (left -2- and right -1-).

–  Unscrew bolted connections -1 … 4- and remove rear cross member on vehicle underside.

–  Unscrew bolted connections -1 … 6- and remove front cross member on vehicle underside.   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. –  Disconnect exhaust system at clamp -arrows-. –  Remove heat shield for exhaust system.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -1- between lifting column and gearbox). –  Support the tunnel cross member with engine and gearbox jack -V.A.G 1383 A-.   WARNING Injury risk - the lock carrier must be installed on the vehicle.

–  First unscrew bolts -1- and -2-, then bolts -3- and -4-. –  Slowly lower tunnel cross member with engine and gearbox jack -V.A.G 1383 A-.

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

–  Remove heat shield -1- for drive shaft (right-side). –  Unbolt drive shafts (left and right) from gearbox flanges → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Remove bracket -1- for front exhaust pipe. –  Remove bolts -arrows- securing front exhaust pipe to catalytic converter.   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. –  Remove front exhaust pipe.

–  Unbolt bracket for ATF pipes -arrow-.   Note

Observe rules for cleanliness when working on automatic gearbox → Chapter. –  Place drip tray beneath gearbox. –  Remove bolt -arrow- and detach ATF pipes from gearbox. –  Tie ATF pipes to one side.

Vehicles with wiring harness with oval connector: –  Release connector -A- in direction of -arrow- and unplug from gearbox. –  Move wiring harness clear.

Vehicles with wiring harness with round connector: –  Release electrical connector -1- and detach from gearbox. –  Move wiring harness clear -arrows-.

All models: –  Unscrew bolts -2- and remove bracket -3- for selector lever cable.

–  Use removal lever -80-200- to prise selector lever cable -A- off gearbox selector lever -arrow-.

–  Unscrew bolts -2- and detach gearbox support -1- from gearbox.

–  Remove bolts -1 ... 5- and -11- from engine/gearbox flange. –  Only slacken bolt -Item 6- and leave it in position (finger-tight).   Note The starter does not have to be removed.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/30- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements as illustrated on adjustment plate.

–  Place engine and gearbox jack -V.A.G 1383 A- with gearbox support -3282- underneath gearbox and support gearbox.   Note The arrow symbol on the adjustment plate points in the direction of travel. –  Align adjustment plate parallel to gearbox and secure support to gearbox with bolt M10 x 20 -arrow-. –  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

–  Remove bolts -7 ... 10- from engine/gearbox flange. –  Lower gearbox again slowly. –  Tie up drive shafts. –  Remove the last engine/gearbox securing bolt. –  Press gearbox off dowel sleeves and lower it carefully.