Note: If for any reason the flywheel was removed from the crankshaft, tighten the mounting bolts as follows: bolts without shoulder - 98 Nm bolts with shoulder - 73 Nm. Lubricate threads with sealant to secure.
Gearbox elements (Quattro)
1 gearbox housing (basic)
2 Transmission housing (intermediate)
3 Transmission housing (rear)
4 shift fork
5 Toothed sleeve
6 Sleeve
7 Retaining ring
8 Blocker
9 Spring
10 3rd gear
11 Needle bearing
12 Cuff
13 Input shaft
14 Needle bearing
15 Retaining ring
16 ball bearing
17 Retaining ring
18 Cone washer
19 Oil seal
20 Synchronizer sleeve
21 Blocker
22 Spring
23 Needle valve
24 4th gear
25 Roller with bevel gear
26 Gear shaft
Model 100
Withdrawal
Disconnect the negative wire from the battery.
Remove the upper gearbox-to-engine bolts.
Attention: When removing, mark all the bolts, so that when installing them, put them in their original places, because they are all different sizes.
Disconnect the ground bus from the gearbox, if equipped.
Disconnect the connectors from the speedometer sensor and the multifunction switch.
Support the engine.
Disconnect the wires from the oxygen sensor and the oxygen sensor heating element.
Raise and support the vehicle securely. If there is, remove the mudguard.
Disconnect the exhaust pipe from the manifold.
Separate the exhaust pipe behind the catalytic converter and remove the pipe and catalytic converter.
Remove the shift rod bolt on the gearbox and separate it.
Remove the heat shield from the right inner CV joint.
Remove the axle shafts from the flanges and move them to the side.
Support the gearbox with a suitable object.
Remove the spacer at the rear of the gearbox.
Remove clutch slave cylinder. Do not remove the pipeline from it.
Remove additional frame.
Remove the lower gearbox mounting bolts on the engine.
Press the gearbox back and lower it.
Remove checkpoint.
Installation
Install the gearbox, making sure that the guide bushings are in the cylinder block
Tighten the gearbox mounting bolts as follows:
- M8 bolts - torque 24 Nm.
- Bolts M1 - torque 45 Nm.
- Bolts M12 - torque 65 Nm.
Install additional frame.
Tighten the additional frame mounting bolts to 34 Nm and an additional 90°.
Install the spacer on the rear of the gearbox. If necessary, prop up the gearbox.
Install the clutch slave cylinder.
Attention. The bolt for mounting the clutch slave cylinder is made by Audi and is pointed for ease of installation.
Install the axle shafts. Tighten the bolts securing them to the flanges to 45 Nm and to the gearbox to 54 Nm.
Install the shift rod to the gearbox.
Install exhaust system.
Install all wires, heat shield and motor protection plate.
Install a ground strap, if available. Connect wires to AB. Bleed air from brakes. Test the car in motion.
Model 200
Withdrawal
Disconnect the negative wire from the battery.
Remove the upper gearbox-to-engine bolts.
Remove the plug from the speedometer sensor by squeezing the clamps.
Remove the clamp from the clutch slave cylinder and pull out the spring pin, if present. Remove the clutch slave cylinder bolt and cylinder itself, leaving the hydraulic line connected.
Support the engine. Tie up the coolant hoses and wires, if necessary.
Remove the protective plate on the right.
Disconnect the axle shafts from the flanges and leave them on the additional frame.
Tag and disconnect the wire from the reverse light switch. Disconnect the vacuum hoses from the brake booster, if equipped.
Disconnect the shift rods and adjusting rod.
Remove the lower gearbox-to-engine bolts.
Remove starter.
Remove the protective plate from the additional frame.
Using a suitable jack, slightly raise the gearbox.
Remove the two gearbox support bolts from the subframe.
Remove the bracket from the gearbox, pull the cable of the tension system and the bracket from the mount (retainer) at the checkpoint. The retainer can only be removed when the gearbox is removed from the vehicle.
Remove the right gearbox bracket.
Press gearbox off guide bushings.
Lower the gearbox and remove it from below.
Installation
Installation is made in an order, the return to removal. Before installing the gearbox, leave both axle shafts on top of the additional frame.
Lubricate the splines of the gearbox input shaft.
Install the gearbox on the landing pins and install the lower bolts.
Install the tensioner bracket and cable to the gearbox.
Tighten gearbox bracket bolts and additional frame upper bolts to 39 Nm.
Check the alignment of the gearbox and tighten the bolts of its fastening on the engine to a torque of 54 Nm.
Tighten bolts securing additional frame to body to 108 Nm.
Tighten the axle shaft bolts on the drive flanges to 79 Nm.
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