Removing the gearbox is necessary when replacing the clutch or when repairing or rebuilding the gearbox. We do not recommend repairing the gearbox yourself. The car owner can dismantle the faulty box on his own and deliver it to the workshop.
To remove the gearbox, the vehicle must be raised to a sufficient height.
Withdrawal
1. Disconnect the wire terminal «masses» (-) from the negative pole of the battery.
Vehicles with a V-shaped six-cylinder gasoline engine (biturbo)
2. Unscrew the bolts securing the protective cover above the engine and remove it (see arrows in illustration).
2.2. Unscrew the bolts securing the protective cover above the engine and remove it (see arrows)
Attention! The protective cover consists of three parts (see A, B and C in illustration 2.2).
3 Remove the supply air duct by disconnecting the adsorber purge hose 1 from it, unscrewing the bolts 3 and loosening the clamps 2 (see illustration).
2.3. Remove the supply air duct by disconnecting the adsorber purge hose 1 from it, unscrewing the bolts 3 and loosening the clamps 2
4. Unscrew bolts of fastening of a broad tank of system of cooling and shift it aside, without disconnecting hoses, the corresponding chapter see.
5. Disconnect the plugs 1 of the lambda probes on the exhaust manifolds of the right and left heads and release their wires from the holders (see illustration).
2.5. Disconnect the plugs 1 of the lambda probes on the exhaust manifolds of the right and left heads
6. Unscrew both bolts 2 fastening the heat shield above the right and left exhaust pipes (see illustration).
2.6. Unscrew both bolts 2 fastening the heat shield above the right and left exhaust pipes
7. Unscrew nuts 3, fixing the right and left exhaust pipes, and also unscrew the upper bolts that connect the gearbox to the engine (see illustration 2.6).
8. Place the vehicle on jack stands and remove the engine compartment protection (see arrows in illustration).
2.8. Remove the engine compartment protection (see arrows)
9. Unscrew the bolts and remove the engine compartment protection bracket (see arrow in illustration).
2.9. Unscrew the bolts and remove the engine compartment protection bracket (see arrow)
10. Unscrew the bolts and disconnect the protective shields from the gearbox above the right and left drive shafts (see arrows in illustration), and then unscrew the bolts and disconnect the right and left drive shafts 1 from the box.
2.10. Unscrew the bolts and disconnect the protective shields from the gearbox above the right and left drive shafts (see arrows)
11. Loosen the clamps/couplings on the exhaust system and move the clamps onto the pipes.
12. Unscrew the bolts and remove the protective shield over the cardan shaft (see arrows in illustration).
2.12. Unscrew the bolts and remove the protective shield over the cardan shaft (see arrows)
13. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines (see illustration).
2.13. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines
14. Remove the bolts (see arrows in illustration), that secure cross member A to the bottom, and remove it.
2.14. Unscrew the bolts (see arrows), which secures the cross member A to the bottom, and remove it
15. Unscrew bolts 4 and 5 and remove brackets B, on which the exhaust pipes are held (see illustration).
2.15. Unscrew bolts 4 and 5 and remove brackets B, on which the exhaust pipes are held
16. Place a suitable support under the gearbox.
17. Unscrew the bolts 1 and 2 of the left and right connecting brackets A of the subframe and remove the brackets (see illustration 2.15).
18. Lower the rear of the subframe down about 50mm (cm. «A» in the illustration) and insert a wooden wedge between the subframe and the power block.
2.18. Lower the rear of the subframe down about 50mm (cm. «A»)
19. Unscrew bolts 1 and 2 and remove the right and left gearbox supports (see illustration).
2.19. Unscrew bolts 1 and 2 and remove the right and left gearbox supports
20. Loosen the clamp 3, lift the shield 2 and unscrew the lower nuts 5 securing the exhaust pipe to the exhaust manifold (see illustration).
2.20. Loosen the clamp 3, raise the shield 2 and unscrew the lower nuts 5 that secure the exhaust pipe to the exhaust manifold
21. Lift the shield 2 up and disconnect the downpipe with catalyst 4 from the exhaust manifold (see illustration 2.20).
Attention! Make sure that when disconnecting the pipe, the lambda probe 1 passes through the cutout in the shield 2 (see illustration 2.20).
Attention! It is not allowed to bend the flexible connecting element of the intake pipe at an angle of more than 10". Otherwise, this element is damaged.
22. Raise the gearbox with the support installed under it slightly up to unload the two lower M10x60 bolts with heads for a hex socket key securing the gearbox to the engine and unscrew them (see arrows in illustration).
2.22. Unscrew the two lower bolts securing the gearbox to the engine (see arrows)
Attention! When installing the gearbox, replace these bolts with new M10x55 hex bolts to ensure the correct tightening torque.
23. Lower the gearbox down on the support.
24. Unscrew the tachometer sensor mounting bolt on the left side of the gearbox and move the sensor to the side (see arrow in illustration).
2.24. Unscrew the tachometer sensor mounting bolt and move the sensor to the side (see arrow)
25. Disconnect the speedometer sensor and reversing light switch connector.
26. Unscrew the starter mounting bolts and move it forward as far as possible without disconnecting the wires from it.
27. Unscrew the connecting bolt 2 of the gearshift rod on the right side of the gearbox, as well as the bolt 1 with a head for a hex socket key for fastening the rod (see illustration).
2.27. Unscrew the connecting bolt 2 of the gearshift rod, as well as the bolt 1 with a head for a hexagon socket wrench for fastening the rod
28. Unscrew the nut 1 and remove the lever 2 of the gearshift rod from the rod (see illustration).
2.28. Unscrew the nut 1 and remove the lever 2 of the gearshift rod from the rod
29. Unscrew all remaining lower bolts securing the gearbox to the engine, leaving only two bolts.
2.29. Support VAG 1383A for removing the gearbox with fasteners A and adjusting plate 3282/12
Attention! The car manufacturer recommends that at this stage, to remove the gearbox, install a special support under it with the appropriate fasteners and the so-called adjustment plate (see illustration 2.29). In the absence of such a support, the gearbox should be securely fastened to an already installed support in order to remove the gearbox from under the car on it.
30. Make sure that all wires, hoses and other connections on the gearbox are disconnected and will not be damaged when lowering the gearbox from the engine compartment.
31. Unscrew the two remaining bolts securing the gearbox to the engine and lower the gearbox down until the clutch slave cylinder becomes accessible.
Attention! This operation must be carried out carefully so as not to damage the cylinder piping.
32. Unscrew the clutch slave cylinder bolt (see arrow in illustration) and move the cylinder back without disconnecting the pipeline from it.
2.32. Remove the clutch slave cylinder bolt (see arrow) and move the cylinder back
33. Separate the engine and gearbox, lower the box on the support down and take it out from under the car.
V8 petrol vehicles
34. Remove the bolts (see arrows in illustration) fastening the expansion tank 3 of the cooling system, disconnect the plug of the coolant level sensor and move the tank to the side without disconnecting hoses 1 and 2 from it.
2.34. Unscrew the bolts (see arrows) expansion tank 3 of the cooling system, disconnect the plug of the coolant level sensor and move the tank to the side
35. Release the plug of the lambda probe on the exhaust manifold of the left cylinder head from the holder and disconnect it (see arrow in illustration). Move the wires down.
2.35. Release the plug of the lambda probe on the exhaust manifold of the left cylinder head from the holder and disconnect it (see arrow)
36. Unscrew nuts of fastening of reception pipes to final collectors available from above a motor compartment.
37. Unscrew the bolts securing the air intake 1 to the upper cross member of the front end (see arrows in illustration), disconnect the air intake and remove the air filter cover.
2.37. Unscrew the bolts securing the air intake 1 to the upper cross member of the front end (see arrows)
38. Disconnect the plug 3 of the mass air flow sensor and release the canister purge valve 2 from the holder on the air filter housing (see illustration).
2.33. Disconnect the plug 3 of the mass air flow sensor and release the canister purge valve 2 from the holder
39. Disconnect hose 1 of the afterburning system from the air filter housing by turning the fitting counterclockwise (see illustration 2.38).
40. Disconnect the supply air duct from the throttle valve, and on the right side of the engine, the low pressure hose.
41. Remove the bolt (see arrow in illustration 2.38) attaching the air filter housing to the body and remove it.
42. Release the plug of the lambda probe on the exhaust manifold of the right cylinder head from the holder and disconnect it (see arrow in illustration). Move the wires down.
2.42. Release the plug of the lambda probe on the exhaust manifold of the right cylinder head from the holder and disconnect it (see arrow)
43. Install the car on jack stands and remove the engine compartment protection and protection mounting bracket (see illustrations 2.8 and 2.9).
44. Unscrew the bolts and disconnect the protective shields above the right and left drive shafts from the gearbox, and then unscrew the bolts and disconnect the right and left drive shafts from the gearbox 1 (see illustration 2.10). Tie the drive shafts with wire to the body so that they do not sag.
45. Unscrew the nuts of fastening to the exhaust manifolds on the left and right cylinder heads of the exhaust pipes (see arrows in illustration).
2.45. Unscrew the nuts securing to the exhaust manifolds on the left and right cylinder heads of the exhaust pipes (see arrows)
46. Unscrew the bolts 1 and 2 of the brackets of the exhaust pipes to the gearbox and disconnect the exhaust pipes from the exhaust manifolds (see illustration).
2.46. Unscrew bolts 1 and 2 of fastening to a transmission of arms of reception pipes
Attention! It is not allowed to bend the flexible connecting element of the downpipe by more than 10°.
47. Loosen bolts 1 and 2 of the connecting clamps / couplings on the exhaust pipes, move them back and remove the exhaust pipes with catalysts and lambda probes (see illustration).
2.47. Loosen bolts 1 and 2 of the connecting clamps/couplings on the exhaust pipes and remove the exhaust pipes
48. Unscrew the bolts and remove the protective shield over the cardan shaft (see arrows in illustration 2.12).
49. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines (see illustration 2.13).
50. Place a suitable support under the gearbox and raise it slightly to relieve its suspension mounts (see illustration).
2.50. Place a suitable support under the gearbox and raise it slightly to relieve the load on its suspension mounts
51. Unscrew bolts 1 and 2 and remove the right and left gearbox supports (see illustration 2.19).
52. Raise the gearbox a little more and unscrew the two lower bolts securing the gearbox to the engine (see illustration 2.22).
53. Lower the gearbox down to its original level and unscrew all the bolts connecting the gearbox to the engine, leaving only two for insurance.
54. Unscrew the connecting bolt 2 of the gearshift rod and the bolt 1 with a hexagonal socket head for 8 mm of the rod fastening, and also disconnect the plug 3 of the reversing light switch (see illustration).
2.54. Unscrew the connecting bolt 2 of the gearshift rod and the bolt 1 with a socket head for fastening the rod
55. Remove the protective shield over the tachometer / crankshaft position sensor, unscrew the mounting bolt, remove the sensor and move it to the side (see illustration 2.24). The sensor is located on the left side of the gearbox.
56. Disconnect the speedometer sensor plug (see arrow in illustration).
2.56. Disconnect the speedometer sensor connector (see arrow)
57. Unscrew the nut 1 and remove the lever 2 of the gearshift rod from the rod (see illustration 2.28).
58. Unscrew the clutch slave cylinder bolt (see arrow in illustration 2.32) and move the cylinder back without disconnecting the pipeline from it.
59. Unscrew the mounting bolts and disconnect the transmission fluid pipelines from the gearbox (see arrows in illustration). Plug the openings of the pipelines with suitable plugs.
2.59. Unscrew the mounting bolts and disconnect the transmission fluid pipelines from the gearbox (see arrows)
60. Unscrew the pipe holder bolt (see arrow in illustration), move the pipes to the right and secure to the body with wire.
2.60. Unscrew the pipe holder bolt (see arrow) and move the pipelines to the right
61. Unscrew the remaining two bolts securing the gearbox to the engine, disconnect the engine and gearbox, lower the box on the support down and take it out from under the car.
V6 TDI Diesel Vehicles
Attention! To access the bolts securing the gearbox to the engine, it is necessary to dismantle the exhaust pipe with the catalyst.
62. Remove the protective cover of the engine by unscrewing the mounting bolts (see arrows in illustration).
2.62. Remove the engine cover by unscrewing the mounting bolts (see arrows)
63. Unscrew the bolts and remove the protective shield over the turbocharger (see arrows in illustration).
2.63. Unscrew the bolts and remove the protective shield over the turbocharger (cm, arrows)
64. Unscrew the bolts securing the downpipe to the turbocharger (see arrows in illustration).
2.64. Unscrew the bolts securing the exhaust pipe to the turbocharger (see cuts)
65. Install the car on jack stands and remove the engine protection.
66. Unscrew the bolts of the bracket A (see arrows in illustration).
2.66. Unscrew the bolts of the bracket A (see arrows)
67. Remove the cross member 1, loosen the bolts of the connecting clamp (see arrows in illustration) and remove the intake pipe.
2.67. Remove the cross member 1, loosen the bolts of the connecting clamp (see arrows) and remove the intake pipe
68. Unscrew the top bolts of fastening of a transmission to the engine.
69. Loosen bolt A behind the turbocharger and push bracket B in the direction of the arrow (see illustration). Then tighten bolt A.
2.69. Loosen bolt A and move bracket B in the direction of the arrow
70. Unscrew the bolt 2 that secures the shield above the left drive shaft, disengage the grip 1 of the shield and remove the shield (see illustration).
2.70. Remove the shield above the left drive shaft by unscrewing the bolt 2
71. Unscrew the bolts and disconnect the protective shields from the gearbox above the right and left drive shafts (see arrows in illustration 2.10), and then unscrew the bolts and disconnect the right and left drive shafts from the box 1. Tie the shafts with wire to the body so that they do not sag.
72. Unscrew the tachometer sensor mounting bolt on the left side of the gearbox and move the sensor to the side (see arrow in illustration 2.24).
73. Disconnect the speedometer sensor and reversing light switch connector. Release the sensor wires from the holder on the gearbox.
74. Unscrew the starter mounting bolts and move it forward as far as possible without disconnecting the wires from it.
75. Unscrew all the bolts securing the gearbox to the engine, leaving only one for insurance.
76. Unscrew the connecting bolt 2 of the gearshift rod on the right side of the gearbox, as well as the bolt 1 with a hexagonal socket head for fastening the rod (see illustration 2.27).
Attention! Do not remove the ball head when unscrewing the connecting rod 2 (see arrow A in illustration 2.78) from the shift rod 1 if the connecting rod is not set to approximately 11 o'clock. When removed, the ball head is damaged.
77. Unscrew nut B and unscrew bolt C to remove shift rod (see illustration).
2.77. Unscrew nut B and unscrew bolt C to remove the shift rod
78. Unscrew the nut 1 and remove the lever 2 of the gearshift rod from the rod (see illustration 2.28).
79. Unscrew the bolts and remove the protective shield over the cardan shaft (see arrows in illustration 2.12).
80. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines (see illustration 2.13).
81. Unscrew bolts 1 and 2 and remove the right and left gearbox supports (see illustration 2.19).
82. Unscrew the remaining bolt securing the gearbox to the engine, shift the gearbox from the mounting bushings on the engine and lower the gearbox on the support down so that the clutch slave cylinder becomes accessible.
Attention! This operation must be carried out carefully so as not to damage the cylinder piping.
83. Remove the clutch slave cylinder bolt (see arrow in illustration 2.32) and move the cylinder back without disconnecting the pipeline from it.
84. Separate the engine and gearbox, lower the box on the support down and take it out from under the car.
Installation
85. Before installing the gearbox, check the condition of the clutch pressure and driven discs.
86. Clean off corrosion and apply a thin film of molybdenum grease or AUDI-G 000100 grease to the spline of the driven disc hub, as well as to the gear rim of the gearbox input shaft.
Attention! The clutch disc must move easily on the input shaft. Excess grease must be removed.
87. Check the condition of the clutch release bearing and replace it if necessary
88. Check the presence of the alignment pins for the gearbox on the engine. Install pins if necessary.
89. Install the gearbox on a support under the engine compartment, lift it and insert the input shaft of the box into the splined hole of the clutch disc, holding the box horizontally. If the splines of the hub of the driven disk and the input shaft do not match, then turn the shaft by the flange by hand.
90. Reinstall the clutch slave cylinder and press it together with the pipe holder with a pry bar until the mounting bolt can be screwed in.
91. Install the starter and screw in the upper bolts of the box to the engine (see illustrations 2.91, 2.91a and 2.91b).
2.91. The moments of an inhaling of bolts of fastening of a transmission to the engine
92. Screw in and tighten the three lower engine and gearbox mounting bolts
93. Reinstall and secure the drive shafts.
94. Reinstall the protective shields of the right and left drive shafts by screwing in the bolts with a force of 20 Nm.
95. Connect and bolt the linkage and shift rod to the gearbox.
96. Connect the plugs of the speedometer sensor and the reversing light switch.
97. Connect a reception pipe.
98. Check the transmission fluid level in the gearbox.
99. Adjust the gearshift mechanism.
100. Reinstall the engine mudguard holder.
101. Reinstall mudguard.
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