Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 2.7 ltr. TDI engine Special tools and workshop equipment required

t  Assembly aid -T40169-

t  Transportation lock -T40170-

t  Ring spanner insert, 16 mm -V.A.G 1332/14- Procedure   Note t  Renew bolts which are tightened by turning through a specified angle. The aluminium bolts securing the engine to the gearbox can be used twice only. t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets. t  Hose connections and hoses for charge air system must be free from oil and grease before fitting. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. t  Re-attach all cable ties at the same locations when re-installing.

t  Check input shaft of removed gearbox for scoring around bearing in drive plate -arrow-. Renew needle bearing in drive plate if necessary → Rep. gr.13. Tightening torques for installing gearbox: → Anchor

–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. l  Check whether aluminium bolts -2 … 11- can be reused for engine/gearbox connection and mark bolts if necessary → Anchor.

–  Install clutch module if previously removed → Servicing 6-speed manual gearbox 0B3, front-wheel drive; Rep. gr.30.

–  Position gearbox on gearbox support -T40173- and secure with tensioning strap -1-, as shown in illustration.

–  The following preparations must be made before joining the engine and gearbox: –  Insert assembly aid -T40169- into gearbox housing and clutch module from below, as shown in illustration. l  The assembly aid -T40169- must engage in the semi-circular recess -1- and in the inspection hole -2-.   Note There is only one inspection hole at the periphery; turn the clutch module accordingly. –  Insert pin of assembly aid -T40169- into hole on gearbox housing.

–  Insert transportation lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-.

–  Raise gearbox just far enough to be able to insert clutch slave cylinder. –  Tighten bolt -2- → Item.   Note

The next step is only required if a drive plate with locating pins -2- is installed. –  In addition, align drive plate with clutch module so that locating pins -2- (if provided) on drive plate can engage in large holes -1- on clutch module.   Caution An incorrectly installed clutch causes functional problems. If the locating pins on the drive plate -2- are not located in the holes on the clutch module -1-, this will lead to considerable functional problems of the clutch.

–  Join gearbox with engine and tighten bolts -3 ... 11-; tightening torques → Anchor. –  Fit starter and tighten bolt -1- from engine side; tightening torque → Anchor. –  Then tighten bolt -2- from gearbox side to specified torque → Anchor.

–  Release spindle -10 - 222 A /11-.   Note Use stepladder -VAS 5085- for access to spindle -10 - 222 A /11- while vehicle is raised.

–  Raise gearbox using engine and gearbox jack -V.A.G 1383 A- initially only until dimension -a- is reached between tunnel cross member and body. l  Dimension -a- = approx. 100 mm

–  Secure drive shafts (left and right) to flange shafts on gearbox → Rep. gr.40. –  Install heat shield for drive shaft and tighten bolts -arrows- to 23 Nm.

–  Secure push rod -1- → Item. –  Plug in connector -2- at gear detector switch -F208-. –  Align connecting rod -3- as illustrated.

–  Install gearbox selector lever -2- as follows: l  Gearbox selector lever -2- can only be fitted onto selector shaft -1- in one position (gap in splines -arrow-). –  Secure gearbox selector lever -2-. Tightening torque → Item

–  Raise gearbox further and tighten bolts -arrows- for tunnel cross member; tightening torques → Chapter. Detach engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- from gearbox.

Tightening sequence – clutch module to drive plate –  Remove assembly aid -T40169- and transportation lock -T40170-. –  Engage 6th gear by pulling out selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.   Note

The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant. –  Turn both front wheels together in one direction until the clutch module has turned through one complete revolution (360°). l  The inspection hole -arrow- should be visible again in the recess on the gearbox housing.

Secure clutch module to drive plate as follows: l  Use new bolts. l  Tightening torque → Item l  Tighten bolts using ring spanner insert, 16 mm -V.A.G 1332/14-. –  Install first bolt -arrow- and tighten hand-tight (2 Nm). –  Turn both front wheels so that clutch module/drive plate turns 180° further. –  Now install second bolt and tighten to specified torque → Item. –  Now install remaining bolts securing clutch module to drive plate all round, and tighten immediately to specified torque (also tighten the first bolt installed) → Item.

The remaining installation steps are carried out in reverse sequence; note the following: –  Secure universal joint -arrow- to steering box → Rep. gr.48.

–  Secure connecting rod -3- from above, from where plenum chamber partition panel was previously removed → Chapter.   Note Items marked -2- and -3- can be disregarded.

–  Install particulate filter and front exhaust pipe → Rep. gr.26. –  Align exhaust system so it is free of stress → Rep. gr.26. –  Install plenum chamber partition panel → Rep. gr.50. –  Install body brace → Rep. gr.40.

–  Install subframe cross brace → Rep. gr.40. –  Check gear oil level in gearbox → Chapter. –  Install noise insulation → Rep. gr.66. –  Observe correct procedure after connecting battery → Rep. gr.27.   Caution Overvoltage can cause irreparable damage to control units. Do not use charger for boost starting. –  Fill up with coolant if necessary → Rep. gr.19. 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 %. Other tightening torques:

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65

Engine/gearbox securing bolts

Item	Bolt	Nm
1 1)	M10 x 50 2)	65
2 1)	M12 x 100 3)	30 + 90°
3 … 6	M12 x 100 3)	30 + 90°
7	M12 x 125 3)	30 + 90°
8, 11	M10 x 60 3)	15 + 90°
9, 10	M10 x 95 3)	15 + 90°
A	Dowel sleeves for centralising
l  1) Also secures starter. l  2) Steel bolt - do not renew. l  3) Check whether aluminium bolts can be reused → Anchor and renew if necessary.

Checking whether aluminium bolts can be reused t  Aluminium bolts -2 … 11- can be used twice only. After they have been used once, an „X“-arrow- must therefore be chiselled onto the bolts. t  To prevent damage to the bolts, they must not be clamped in a vice when marking them. Clamp a 14 mm socket with 1/2" drive in the vice instead, and insert the bolt into the socket, as shown in illustration. t  Bolts marked with an „X“ must not be used again. t  The steel bolt -1- can be re-used any number of times.