TorqFix

Gearbox removal & installation: Audi 1.6 (BAD)

Step-by-step gearbox removal & installation for the Audi 1.6 (BAD): 29 steps. What to remove, in what order, and what to check after.

Workshop procedure for AUDI — the exact step sequence and torque figures, straight from real workshop data.

29 steps 1 engine code

🧭 Before you start

Fits: Audi A2 (8Z)

Don't miss

  • Ensure that intermediate plate is engaged on sealing flange (arrow A) and pushed onto dowel sleeves (arrows B).
  • Make sure there is sufficient clearance for gear selector cables and engine wiring harness when lifting engine/gearbox assembly.
  • Avoid damage to clutch slave cylinder.Do not operate clutch pedal with slave cylinder removed. — Install clutch slave cylinder 30.
  • Do not use drained coolant again if:the cylinder head or cylinder block have been renewed.the coolant is contaminated or dirty.

🔧 Engine codes this applies to

BAD

📐 27 workshop diagrams for BAD

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 1
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 2
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 3
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 4
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 5
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 6
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 7
4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Installing engine — BAD · diagram 8
+ 19 more diagrams
🔒 27 workshop diagrams for this job Ask about your Audi BAD — free or sign up free to see the drawings

📋 Procedure

  1. If not already fitted, install dowel sleeves for centring engine and gearbox in cylinder block.
  2. Ensure that intermediate plate is engaged on sealing flange (arrow A) and pushed onto dowel sleeves (arrows B).
  3. Clean the input shaft splines and the hub splines. Remove corrosion and apply only a very thin coating of greaseG 000 100 to the splines. Remove any excess grease.
  4. Check clutch release bearing for wear; renew if necessary 30.
  5. Check oil seal for flange shaft (right-side) for leaks; renew if necessary 39.
BAD? Steps differ between engine variants — check this job against your exact car before you commit to it. Check my car — free →
  1. Secure gearbox to engine.
  2. Install flange shaft (right-side) 39.
  3. Install starter 27
  4. Install bracket for exhaust manifold .
  5. Make sure there is sufficient clearance for gear selector cables and engine wiring harness when lifting engine/gearbox assembly.
  6. Guide engine/gearbox assembly into body.
  7. Install gearbox mounting 34.
  8. Install engine mountings .
  9. Remove engine support T40075 from engine.
  10. Install pressure control valve for crankcase breather system .
  11. Install support for intake manifold 24.
  12. Install pendulum support .
  13. Install drive shafts and swivel joints 40.
  14. Install air conditioner compressor 87.
  15. Install poly V-belt .
  16. Install front exhaust pipe .
  17. Electrical connections and routing .
  18. ⚠ Avoid damage to clutch slave cylinder.Do not operate clutch pedal with slave cylinder removed. — Install clutch slave cylinder 30.
  19. Install and adjust gear selector cable and gate selector cable 34.
  20. Install radiator fan .
  21. Install connection with guide tube for oil dipstick and oil filler pipe .
  22. Observe notes on procedure for connecting the battery 27.
  23. Check engine oil level 809.
  24. ⚠ Risk of irreparable damage to control units because of excessive voltage.Never use battery charging equipment for boost starting. — Fill up with coolant . [Note: Do not use drained coolant again if:the cylinder head or cylinder block have been renewed.the coolant is contaminated or dirty.]
Workshop diagrams

Ask TorqFix about your Audi BAD — it answers with the exact sequence for that engine and the workshop drawing for each step. First question is free after a 20-second sign-up, no card.

Ask about your Audi BAD — free → or sign up free to see the drawings

Other AUDI procedures

Who makes these pages, and how

TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.

The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.

Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.

Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com

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Workshop data on this page last updated 20 Sep 2026.