Audi Workshop Service and Repair Manuals

Removing and installing sensor module for senders and sensors -G612-/ -G632-/ -G676- Special tools and workshop equipment required t  Counterhold tool -T40217- t  Bit -T40228- t  For sealant, refer to → Electronic parts catalogue

Removing l  Gearbox is secured to engine and gearbox support -VAS 6095- → Chapter. –  Remove flywheel → Chapter. –  Remove dual clutch → Chapter. –  Remove mechatronic unit for dual clutch gearbox -J743- → Chapter. –  Remove centre differential housing and centre differential → Chapter.

–  To remove connector housing for sensor module fit bit -T40228- onto connector housing and turn anti-clockwise (-arrow A-) as far as stop. –  Pull connector housing for sensor module off in direction of -arrow B-.

–  Detach oil duct for input shaft -arrow-.

–  Loosen twelve-point bolt -A- securing side shaft -B- to pinion shaft as follows: –  Apply twelve-point socket -C- (21 mm) with extension -D- to twelve-point bolt -A-. –  Engage external teeth -arrow 1- of counterhold tool -T40217- in internal splines -arrow 2- of side shaft.

–  Secure counterhold tool -T40217- to intermediate gearbox housing -arrows-. –  Loosen bolt for side shaft.   Note The bolt has a high release torque.

–  Remove bolt -1- and take out side shaft -2-.

–  Detach spur gear -1- and needle bearing -2- from output shaft -3-.

–  Wrap adhesive tape -arrow- around outer input shaft to protect oil seal for input shaft. –  After attaching adhesive tape, lubricate tape lightly with grease.

–  Bring gearbox housing into a vertical position on engine and gearbox support. l  Clutch end faces downwards.

–  Remove bolts -arrows- for intermediate gearbox housing all around circumference.

–  Suspend intermediate gearbox housing -1- with gear cluster on workshop hoist -VAS 6100-, as shown in illustration.   WARNING Risk of accident if parts of the lifting equipment are not correctly secured. t  Eye-head bolt -3368- and -VW 771/40- are not properly secured unless the corresponding threads are screwed in all the way. t  Secure hooks and locating pins of lifting tackle -2024 A- with locking pins. –  Detach intermediate housing from gearbox housing slowly and carefully. –  Place intermediate gearbox housing down on workbench.

–  Remove bolt -arrow- and detach sensor module-2-.   Note Oil collector (front) -1- is attached and removed together with sensor module. –  Release retaining tab and detach oil collector (front) -1- from sensor module.

Installing l  Tightening torques → Chapter „Exploded view - dismantling and assembling gearbox“   Note t  Renew bolts which are tightened by turning through a specified angle. t  Depending on version, different types of sensor module and securing bolt are installed. Select correct type → Electronic parts catalogue. –  Wrap adhesive tape -arrow- around outer input shaft to protect oil seal for input shaft. –  After attaching adhesive tape, lubricate tape lightly with grease.

–  Insert sensor module in guide holes and secure -arrow-.

–  Insert oil collector (front) into holes on intermediate housing and into guide on sensor module-arrows-. l  Oil collector should engage audibly.

Preparations for installing electrical connector for sensor module:   Note Renew O-rings on electrical connector -2- for sensor module if sensor module is not being renewed. –  Check that electrical connector -2- is properly engaged in bracket -1- for sensor module. –  Slide connector housing -3- onto connector until it engages audibly; do not turn.

–  Bring gearbox housing into a vertical position on engine and gearbox support.

–  Move gearbox selector lever as far as stop in direction of travel -arrow-.

–  Check that dowel sleeves -1- and -2- are fitted in gearbox housing. –  Apply a thin coat of sealant evenly to flange of gearbox housing -arrow-. For sealant, refer to → Electronic parts catalogue.

–  Check that magnet -arrow- is fitted in gearbox housing.

–  Insert oil duct for front axle drive into gearbox housing. l  Oil duct must be inserted into holes in gearbox housing at three locations -arrows-.

–  Screw guide pins M8 -T10273- into threaded holes below dowel sleeves.

–  Suspend intermediate gearbox housing -1- with gear cluster on workshop hoist -VAS 6100-, as shown in illustration.   WARNING Risk of accident if parts of the lifting equipment are not correctly secured. t  Eye-head bolt -3368- and -VW 771/40- are not properly secured unless the corresponding threads are screwed in all the way. t  Secure hooks and locating pins of lifting tackle -2024 A- with locking pins. –  Lower intermediate housing slowly and carefully into gearbox housing.

–  While lowering intermediate housing, make sure that electrical connector -1- is kept straight and is inserted into hole -arrow- on gearbox housing.   Note For greater clarity, the illustration shows this procedure looking towards the gearbox housing; however you should observe the procedure looking towards the intermediate housing.

–  Guide intermediate housing into position until it makes full contact with gearbox housing and secure with bolts → Fig..

–  Fit connector housing onto connector and engage in clockwise direction -arrow- using bit -T40228-.

–  Fit needle bearing -2- and spur gear -1- onto output shaft -3-.

–  Insert side shaft -2- and bolt -1- into intermediate gearbox housing.

–  Insert side shaft -B- all the way onto pinion shaft and into gearbox cover. Tighten twelve-point bolt -A- securing side shaft -B- to pinion shaft as follows: –  Apply twelve-point socket -C- (21 mm) with extension -D- to twelve-point bolt -A-. –  Engage external teeth -arrow 1- of counterhold tool -T40217- in internal splines -arrow 2- of side shaft.

–  Secure counterhold tool -T40217- to intermediate gearbox housing -arrows-. –  Tighten bolt for side shaft.

–  Attach oil duct for input shaft -arrow-. Perform remaining installation steps in reverse sequence of removal. –  Install centre differential housing and centre differential → Chapter. –  Install mechatronic unit for dual clutch gearbox -J743- → Chapter. –  Install dual clutch → Chapter. –  Install flywheel → Chapter.