To remove and install manual transmissions, follow the steps below. Instructions for automatic transmissions are given at the end of the chapter.
Withdrawal
Disconnect the wire «masses» from the battery.
Attention
- When the wires are disconnected from the battery terminals, the data on the recorded malfunctions are erased in the memory blocks of the control devices, therefore, before disconnecting the wires, it is necessary to contact the workshop to recall the malfunctions recorded in it. After connecting the wires to the battery terminals, it is necessary to activate and reprogram the power windows, as well as the position of the rear-view mirrors and seats.
- If the car has a radio with a code, then before disconnecting the wires from the terminals from the battery, check that there is a code to reactivate the receiver. Otherwise, it will be possible to put the radio receiver into operation only at a specialized station.
Unscrew and remove the expansion tank of the cooling system from the bracket and, without disconnecting the hoses from it, move it to the side.
Loosen the clamps and remove the air pipe located between the air filter and the engine.
Models with 1.8-I/150 HP engine
Remove the air filter.
Paint mark the position of the right front wheel in relation to the hub. This is necessary to reinstall the wheel in its original position, as a result of which its balance is maintained. With the vehicle on wheels, loosen the right front wheel mounting bolts, then raise the vehicle, unscrew the bolts and remove the right front wheel.
Remove the lower mudguard of the engine compartment.
Unscrew the bolts and remove the bracket for the lower mudguard of the engine compartment (see fig. 6.2).
Unscrew and remove the exhaust pipe and catalytic converter.
Unscrew and remove the engine crankshaft speed sensor located on the left side of the gearbox.
If present, unscrew the bolts and remove the protective covers of the right and left drive shafts (see fig. 6.3).
Unscrew bolts and disconnect internal hinges of shafts of a drive from drive flanges of a transmission. Using soft wire, tie the inner ends of the drive shafts to the body. It is not recommended to lower the drive shafts freely, as this may damage the external constant velocity joints (SHRUS)
Remove the starter.
Attention. It is not necessary to disconnect the wires from the starter if it is unscrewed and wired to the body.
Unscrew fixing bolt A (pic. 6.4) transmission control rods and remove the transmission control rods.
Remove bolt B (pic. 6.4) with an Allen socket and disconnect the shift rod from the gearbox.
Disconnect the ground wire from the gearbox.
Disconnect the electrical connectors for tachometer A and reversing light B from the transmission (pic. 6.5).
Unscrew the bolts securing the gearbox to the engine, leaving bolts A and B in place (pic. 6.6).
Install a special hoist with socket 3282 and adjusting plate 3282/10 for gearbox 012/01A and mounting elements under the gearbox. Screw the gearbox to the socket and adjusting plate (see fig. 6.7). Raise the VAG1383A lift just enough so that the weight of the gearbox is supported by the lift.
Attention. In the absence of special tools for removing the transferred box, support the transferred box with a jack through a wide wooden block.
Models with 4-cylinder engines
Loosen bolts A (pic. 6.8) fixing the right rubber-metal gearbox support. Unscrew bolt B (pic. 6.8) mounting bracket from the left gearbox support.
Models with V6 petrol engines
Unscrew bolts of fastening of the right and left rubber-metal bearings of a transmission (see fig. 6.9).
Unscrew the remaining two bolts A and B (pic. 6.6), securing the gearbox to the engine.
Press the gearbox away from the engine, remove it from the centering bushings and lower it 15 cm until the clutch slave cylinder is accessible.
Unscrew the clutch slave cylinder and tie it to the body with a soft wire (see fig. 6.10).
Attention. The hydraulic hose remains connected to the clutch slave cylinder, otherwise it will need to be bled after installation. With the clutch slave cylinder removed, do not depress the clutch pedal.
Carefully lower the transmission and remove it from under the vehicle.
Installation
Attention. Gearbox housings can be made from both aluminum and magnesium alloy. Depending on the material of the gearbox housing, it is necessary to coordinate all parts connected to the gearbox, including bolts and screws. If aluminum alloy crankcase parts are installed in a magnesium alloy crankcase, the crankcase will corrode. This also applies to the bolts securing the gearbox to the engine, which must be coated with a special protective layer for magnesium alloy crankcases. If the gearbox crankcase is made of magnesium alloy, there is an inscription Mg AI9 Zn 1 near the oil filler plug.
Before installing the gearbox, check the condition of the clutch parts.
Clean the spline of the gearbox input shaft and lubricate with a thin coat of MoS2 grease or AUDI 000 100.
Attention. The lubrication layer should be thin and the clutch drive plate should move easily along the gearbox input shaft. Wipe off excess grease, as it will be thrown onto the clutch surfaces during clutch operation, which may interfere with its operation.
Apply a light coat of grease to the pushrod head mating with the clutch release fork.
Check that the gearbox centering bushings are installed in the engine block and install them if necessary.
Check the position of the intermediate shield of the engine.
Raise the gearbox and move it towards the engine, while the input shaft of the gearbox should fit into the grooves of the clutch disc. It may be necessary to rotate the engine crankshaft slightly to align the transmission input shaft splines with the clutch disc splines. When installing the gearbox, the input shaft must not hang on the clutch disc.
Install and secure the clutch slave cylinder with the pipeline bracket. Press the gearbox against the engine, insert the bolts securing the gearbox to the engine, and at this stage tighten the gearbox mounting bolts to 25 Nm.
Install starter.
Tighten bolts of fastening of a transmission to the engine the demanded moment (see fig. 6.11, 6.12).
Connect the ground wire to the gearbox.
Models with 4-cylinder engines
Screw in and tighten in sequence 1,2,3 (pic. 6.13) bolts of fastening of support of a transmission / an arm of units.
Models with V6 petrol engines
Screw in and tighten the bolts of the right and left rubber-metal gearbox mounts (see fig. 6.9). Tighten the bolts of the supports to the gearbox with a torque of 40 Nm, and the bolts of the supports to the brackets - 25 Nm.
Remove the gear box jack.
Connect and screw the drive shafts to the gearbox.
Install the protective covers of the drive shafts and fix them with bolts, tightening them with a torque of 20 Nm.
Install and screw linkage A to the gearbox (pic. 6.4) torque control of 20 Nm and shift rod B with a torque of 40 Nm.
Connect the tachometer and reversing light electrical connectors to the transmission.
Install the exhaust pipe.
Install and secure the expansion tank.
Models with 1.8-1/150 HP engine
Install the air filter.
Install the air pipe with the air flow meter and secure it with clamps.
Connect wire «masses» to the battery. Repeat the operations for memorizing the position of seats, mirrors, etc., as well as set the time on the clock and enter the code into the radio.
Check and, if necessary, top up the oil level in the gearbox.
Install the engine top cover.
Install the lower engine mudguard.
Pic. 6.1. Cross section of a five-speed gearbox
1 - gear wheel of the first transfer,
2 - second gear gear,
3 - third gear,
4 - fourth gear,
5 - fifth gear,
6 - reverse gear,
7 - gearbox housing,
8 - gearbox cover,
9 - input shaft,
10 - output shaft,
11 - ball bearing,
12 - differential,
13 and 14 roller bearings.
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