Table of contents: Removal ↓ Installation ↓
To remove the car, it must be raised to the required height. In addition, to lower the box, a suitable garage lift is required. The process of removing the manual transmission of 1.8 L front-wheel drive engines is described in detail here. Notes on removing the manual transmission for 1.6 L engines, as well as removing the automatic transmission, are given at the end of the Section.
Engines 1.8 l
Removal
1. Disconnect the negative (–) battery cable with the ignition off.
Warning: This will erase information from electronic memory units, such as the radio code. Without the code, the radio can only be switched on by the manufacturer or an AUDI service station. Therefore, please read the materials in the subsection Checking and replacing the generator and voltage regulator brushes.
2. Remove the fan shroud.
3. Disconnect the tachometer sensor connector –1– and the rear fog light switch connector –2–.
4. Loosen the mounting bolts and disconnect the damper and the manual transmission shift drive cable (B).
5. Disconnect the gear selector cable from the guide lever (C) by lifting the tab in the direction of the arrow.
6. Disconnect the slave cylinder hose at the cable support. Unscrew the mounting bolts and disconnect the cable support on the manual transmission (indicated by arrows) and take it aside.
7. Unscrew the 2 mounting bolts and disconnect the slave cylinder from the manual transmission and secure it with the attached hydraulic line on the side of the body.
Warning: Do not disconnect the hydraulic line, otherwise the air must be bled from the hydraulic system after installation. Do not press the clutch pedal when the cylinder is removed.
8. Disconnect the ground wire from the upper bolt –1– connecting the manual transmission/engine. Remove bolt –1–.
9. Disconnect the cable holder –3– at the top of the starter (arrow on the illustration) and take it aside.
10. Unscrew the bolt –2– at the top of the starter.
11. Remove all mounting bolts accessible from above between the engine and the manual transmission.
12. Raise the engine. To do this, install a device, for example, AUDI 10–222A in combination with supports 10–222A/1.
13. Raise the power unit slightly using the screws.
14. If the specified device is not available, place a pipe over the engine compartment and support it on wooden blocks from the side. Do not place the pipe on the wings. Hook the cables to the engine eyes and connect them to the propeller. Tighten the cable.
Warning: There is a danger when lifting and placing the vehicle on stands! Therefore, please read the subsection first Jacking up a car.
15. Raise and support the vehicle. Remove the lower engine compartment cover, referring to subsection Removal and installation the lower engine compartment cover.
16. Remove the starter.
17. Loosen the mounting bolts and remove the power steering drive wire holder from the manual transmission housing.
18. Remove the right drive shaft flange protective cover (A), if equipped.
19. Loosen the mounting bolt (top arrow) small cover behind the right drive shaft and remove the cover.
20. Loosen the drive shaft mounting bolts and disconnect, refer to the subsection Removal and installation drive shafts.
21. Suspend the drive shafts on the wire as high as possible by turning the steering wheel all the way to the left.
Warning: Be careful not to damage the paintwork.
22. Disconnect the exhaust system between the catalytic converter and the center muffler, referring to subsection Replacing the central/additional muffler.
23. Loosen the mounting bolts and disconnect the pendulum support between the body and the side of the engine/transmission (arrow on the illustration).
24. Loosen the mounting bolts and disconnect the left manual transmission support rod (arrow A in the illustration), then disconnect the manual transmission support (arrow B in the illustration).
25. Loosen the transmission support mounting bolts (A) on the gearbox and disconnect. To remove the mounting bolts (indicated by arrows), lower the engine-transmission unit using spindles so that the bolts are accessible from the left wheel arch.
Warning: When lowering the unit, be careful not to damage the power steering lines.
26. Secure the special tool (C) with the bolt (B) at the bottom of the pendulum support mount. Insert the pressing device (A) and secure with the bolts (indicated by arrows). Push the engine-transmission unit forward.
Warning: If a special tool is not available, the engine-transmission unit can be moved forward using a jack. Be careful not to damage the power steering lines.
27. Slightly lift the manual transmission with a lift, for example, AUDI 3282. The manual transmission support brackets are first set according to the 3282/8 adjustment plate. If a manual transmission lift is not available, lift the manual transmission with a garage jack.
Warning: Place a wooden block between the transmission and the jack.
28. Remove the lower mounting bolts between the engine and the manual transmission.
29. Press the manual transmission away from the guide bushings and carefully pull it out.
Warning: When removing the manual transmission, be careful not to damage the power steering line.
Installation
Warning: If the manual transmission is being replaced, transfer the speedometer sensor, gear selector lever and shift lever from the old manual transmission to the new one.
30. Before installing the clutch, check it, referring to the subsection Removal, installation and checking the clutch.
31. Clean and lightly lubricate the manual transmission input shaft with MoS2 or AUDI–G 000 100 grease.
Warning: The clutch disc must move easily on the shaft.
32. Check if the guide bushings for centering the engine/transmission unit are installed in the cylinder block. Insert if necessary.
33. Press the clutch release lever before installing the manual transmission to the manual transmission housing and secure it with a mounting bolt or an M8 x 35 bolt. After installation, unscrew the bolt.
34. Raise the manual transmission and engage its clutch. If the manual transmission primary shaft does not enter the clutch disc, turn the primary shaft by hand from behind the flange. When installing, ensure that the intermediate plate is in the correct position.
35. Turn and remove the special tool or jack.
36. Screw in the bolts securing the manual transmission and starter. To do this, install the starter.
37. Screw in the engine/gearbox assembly mounting bolts as deep as possible.
38. Again, unscrew the M8 x 35 bolt to secure the clutch release lever to the clutch housing. The hole is closed by the drive rod support mounting bolt.
39. Secure the left bracket to the manual transmission by hand and install the engine/transmission into the mounting position using a crane.
40. Hand tighten the engine/transmission mount with new bolts (B).
41. Hand tighten the pendulum support with new bolts.
42. Remove the engine and transmission lifting device.
43. Align the engine/gearbox unit by shaking it vigorously from side to side.
44. Tighten the engine/transmission assembly and pendulum support to the values given in the Specifications. In this case, tighten the bolts first with a torque wrench and then tighten them with a rigid wrench to an angle of 90° (1/4 turn).
Warning: Bolts are subject to residual deformation when tightened. Therefore, new bolts are used after each loosening.
45. Install the drive shafts, referring to the subsection Removal and installation drive shafts.
46. Install the large and small drive shaft covers.
47. Install the left engine mount mounting bolts and tighten to 50 Nm (the illustration shows the location and tightening torques of the gearbox mounting bolts).
48. Install the starter.
49. Fasten the cable support to the manual transmission with bolts to a torque of 25 Nm.
50. Tighten the shift cable to the gearshift lever with a torque of 25 Nm.
51. Connect the selector drive cable to the shift lever.
52. Attach the counterweight to the gearshift lever. Tighten the mounting bolts first with a torque wrench to 20 Nm and then tighten them further with a rigid wrench to an angle of 90° (1/4 turn).
53. Adjust the gear shift drive, refer to subsection Adjusting the shift drive.
54. Secure the connector to the manual transmission, referring to the "Removal" subsection.
55. Connect the connector to the starter.
56. Lubricate the end of the hydraulic drive working cylinder rod with MoS₂ grease. Insert the working cylinder into place and secure it with a torque of 20 Nm
57. Press the clutch pedal several times and check the operation.
Warning: If the hydraulic actuator has been opened, bleed the system.
58. Install the exhaust pipe/catalytic converter with new gaskets, referring to subsection Removal and installation of the exhaust system.
59. Secure the power steering pipe holder to the gearbox housing, referring to the subsection Removal and installation the power steering pump.
60. Check the oil level in the manual transmission, refer to the subsection Checking the transmission oil level of the manual transmission.
61. Install the lower engine compartment cover, referring to the subsection Removal and installation the lower engine compartment cover.
62. Install the air filter housing, referring to the subsection Removal and installation the air filter housing.
63. Connect the negative (–) cable to the battery.
Warning: Activate the automatic safety of the electric windows, enter the code of the radio receiver, set the clock, and refer to the subsection Entering the radio code.
Specially for 1.6L engines
Warning: Description of work and notes concerning all manual transmissions are given in the subsection for 1.8 l engines. This subsection describes only the differences that relate only to the 1.6 l engine. These differences concern, first of all, the shift drive, which for the 1.6 l engine occurs via rods, and for other engines via cables.
64. Raise the engine using a crane, hooking the engine onto the lugs on the cylinder head.
65. Using a screwdriver, disconnect the front tie rod –1– from the lever –2–. Remove the lock washer –3–, remove the console –4–.
66. Detach the console –4– by turning it 90° (1/4 turn) to the right of the rod with damper –5–. Tilt the rod with damper upward and remove it from the bearing support –6–.
67. Using a screwdriver, disconnect the long connecting rods from the gear selector lever (indicated by arrows). Loosen the bolt and disconnect the front shift lever –1– from the manual transmission.
68. Remove bolts –2– and remove shift console –3– with connecting rods and shift lever
69. Disconnect the slave cylinder hose at the support. Unscrew the 2 mounting bolts and disconnect the slave cylinder (indicated by arrows) at the manual transmission and secure it with the attached hose to the body with wire.
Warning: Do not disconnect the hydraulic line, otherwise you will have to bleed the clutch after installing it. After removing the slave cylinder, do not press the clutch pedal.
Warning: After installing the manual transmission, it is necessary to adjust the shift drive, and refer to the subsection Disassembling the drive shaft.
[The original article is posted on the resource: AudiManual]