Automatic gearbox 09G — Removing and installing gearbox — AUDI

🧭 Before you start

Fits: Audi TT Mk1 (8N)

• Renewed: nuts for torque converter, self-locking nuts
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — With ignition switched off, disconnect earth wire (arrow) at battery.
• Do not bend or kink the selector lever cable.
• Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.
• Seal off ATF cooler with clean plugs or sealing caps to prevent dirt from entering.
• The gearbox has no separate flange shaft; the drive shaft is fitted into the gearbox.

📋 Procedure

1. Shift selector lever to position "“N”".
2. Remove engine cover panel (1)(top arrows).
3. Remove cover panel (front left) (arrows).
4. ⚠ When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — With ignition switched off, disconnect earth wire (arrow) at battery.
5. Detach air hose (1) leading to secondary air pump from air cleaner housing.

6. Release hose clip (2) and detach air hose from air mass meter G70.
7. Unplug electrical connector for air mass meter G70(Item 3).
8. Remove bolts (4) and (5) and detach air cleaner housing.
9. Remove battery 27.
10. Remove battery tray (arrows).
11. Use an open-end spanner (10 mm) (item 2) or similar to lever selector lever cable (1) off selector shaft lever (3).
12. Press retainers on support bracket for selector lever cable together (arrows) and pull selector lever cable out of support bracket on gearbox.
13. Unhook selector lever cable (1) from clip (arrow) on gearbox and tie up. [Note: Do not bend or kink the selector lever cable.]
14. Unplug electrical connector at multi-function switch F125.
15. Remove electrical connections from starter.
16. Remove starter (C)27.
17. Mark coolant hoses at ATF cooler for reinstallation. [Note: Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.]
18. Clamp off coolant hoses with hose clamps 3094 and detach hoses from ATF cooler. [Note: Seal off ATF cooler with clean plugs or sealing caps to prevent dirt from entering.]
19. Set up support bracket10 - 222 A with rack10 - 222 A /1 on body flanges (arrows), as shown in illustration.
20. Engage hook of spindle with shackle10 - 222 A /12 in engine lifting eye.
21. Partly take up weight of engine/gearbox assembly via spindle.
22. Unscrew earth connection (arrow).
23. Remove all engine/gearbox securing bolts which are accessible from above.
24. Remove both front wheels.
25. Remove centre noise insulation (loosen fasteners (arrows)).
26. Completely remove drive shaft (left-side) using wedge T1016140. [Note: The gearbox has no separate flange shaft; the drive shaft is fitted into the gearbox.]
27. If fitted, unscrew nuts (arrows) and tie up bracket for front left vehicle level sender G78 to one side.
28. Remove noise insulation (left-side) (arrows).
29. Detach power-steering pressure pipe from tubular cross member (arrows).
30. Unbolt power-steering pressure pipe from gearbox (arrows) and detach speed nut from gearbox.
31. If fitted, remove tubular cross member (arrows).
32. If fitted, remove cross piece from subframe (arrows).
33. First unscrew bolts (A) and then bolts (B) and remove pendulum support.
34. Press swivel joint (right-side) out of wheel bearing housing 40. [Note: This work step is necessary so that the drive shaft (right-side) need not be separated from the wheel bearing (wheel hub).The drive shaft (right-side) only has to be separated from the gearbox.]
35. Remove bolts (B) and detach heat shield (A).
36. Press drive shaft (right-side) (C) off gearbox (arrow) using wedge T1016140. [Note: The gearbox has no separate flange shaft; the drive shaft is fitted into the gearbox.]
37. Lift drive shaft (right-side) (A) up and secure with wire.
38. Unclip cap (C)
39. Remove 6 nuts (arrow) for torque converter (turn crankshaft 60° in direction of engine rotation each time). [Note: If the six nuts have not all been removed from the torque converter, the torque converter will be pulled out when you remove the gearbox from the engine.To loosen the torque converter nuts, counterhold at bolt for vibration damper.]
40. ⚠ The flexible joints in the front exhaust pipe can be damaged.The flexible joints in the front exhaust pipe must not be bent further than 10°. — Loosen nuts (arrows) and move clamp towards rear.
41. Tie up exhaust system using a chain. To do so, engage hooks3004 in openings on underbody (if necessary remove plugs).
42. Unplug electrical connectors (A) and (B). [Note: If electrical connectors (A) or (B) (bolted onto gearbox) are damaged, corresponding wiring harness must be renewed Removing and installing wiring harness with 14-pin connector and Removing and installing wiring harness with 8-pin connector and gearbox oil temperature sender G93.]
43. Unscrew bolts (1) and (2) and detach gearbox support (A).
44. Lower engine/gearbox assembly via spindle (approx. 50 mm).
45. Set up gearbox support3282 on engine and gearbox jackV.A.G 1383 A.
46. Place adjustment plate3282/36 on gearbox support3282 (adjustment plate only fits in one position).
47. Align arms of gearbox support according to holes in adjustment plate.
48. Secure support elements as illustrated on adjustment plate.
49. Place engine and gearbox jackV.A.G 1383 A with gearbox support3282 underneath gearbox and support gearbox.
50. Secure gearbox to gearbox support3282 with bolt (1).
51. Remove rear bolt (B) securing gearbox to engine.
52. Remove remaining engine/gearbox securing bolts.
53. Push gearbox off engine and at the same time press torque converter out of drive plate.
54. Press torque converter against ATF pump (arrow).
55. Carefully pivot gearbox towards subframe.
56. Carefully lower gearbox and guide downwards past subframe.
57. When lowering gearbox, change position of gearbox as required using spindle on gearbox support3282.
58. Secure torque converter in gearbox using support bridge30 - 211 A to prevent it from falling out. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.Do not use parts which have been degreased.Tolerance for tightening torques ±15%.] [Note: Before fitting a replacement gearbox, always clean the ATF cooler.Renew bolts which are tightened by turning through a specified angle.Renew nuts for torque converter.Renew self-locking nuts and bolts, and seals, O-rings and gaskets.Hose connections and hoses for charge air system must be free from oil and grease before fitting.Secure all hose connections with the correct hose clips (as original equipment); refer to Electronic parts catalogue.To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation.]
59. Push the torque converter hub through the oil seal onto the gearbox shaft as far as the first stop.
60. Push torque converter into torque converter bellhousing by hand, turning it so that torque converter hub engages in slots of internal gear of ATF pump. You should feel the torque converter slide into place.

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