Installing gearbox: Audi A3

🧭 Before you start

Prepare the splines, dowels, release bearing and intermediate plate, raise the gearbox on its support and slide it over the flywheel. Fit new engine/gearbox bolts and run the bevel box bracket tightening sequence. Align the mounting support arm parallel, refit subframe, steering box, drive shafts, pendulum support and propshaft, then exhaust, clutch pressure pipe, starter, power steering, selector cables and wiring. Finish with gear oil check, clutch bleeding and selector adjustment.

Fits: Audi A3 (8L, 1996–2003)

• Opens: clutch fluid
• Renewed: if necessary

Don't miss

• Grease the input shaft splines very thinly and remove the excess; surplus grease ends up on the clutch.
• Bevel box bracket: A to 3 Nm, B/C to 35 Nm (C to 22 Nm where specified), then A to 45 Nm.
• Align the mounting support arm and gearbox support exactly parallel before inserting bolts, or the threads are damaged.
• Leave the support bracket in place until both assembly mountings are torqued.
• A damaged propshaft flange seal means a new propshaft; guide the bevel box pin in carefully.
• Do not press the clutch pedal until the clutch system has been bled.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splinesG 000 100 to the splines. It is important to remove excess grease.
2. Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.
3. Check clutch release bearing with hydraulic actuator for wear and renew if necessary.
4. Engage intermediate plate at sealing flange and push onto dowel sleeves (arrows).
5. Tilt gearbox to the left by turning spindles of gearbox support3282.

6. Raise gearbox carefully and move to installation position using gearbox support.
7. Push the gearbox over the engine flywheel at the front first (arrow) and then at the bevel box side.
8. Install gearbox.
9. Install bevel box bracket prior to fitting engine/gearbox securing bolts.
10. Fit new engine/gearbox securing bolts which are accessible from below. Tightening torques
11. Screw in bevel box bracket bolts (A ... C) only a few turns at this stage.
12. Observe the further tightening sequence:
13. First tighten bolts (A) to 3 Nm. — 3 Nm (2.2 lb-ft)
14. Tighten bolts (B) and (C) to 35 Nm. — 35 Nm (26 lb-ft)
15. Tighten bolts (A) to 45 Nm. — 45 Nm (33 lb-ft)
16. Screw in bevel box bracket bolts (A ... C) only a few turns at this stage.
17. Observe the further tightening sequence:
18. First tighten bolts (A) to 3 Nm. — 3 Nm (2.2 lb-ft)
19. Tighten bolts (B) to 35 Nm. — 35 Nm (26 lb-ft)
20. Tighten bolt (C) to 22 Nm. — 22 Nm (16 lb-ft)
21. Tighten bolts (A) to 45 Nm. — 45 Nm (33 lb-ft)
22. Detach gearbox support3282 from gearbox.
23. If fitted, install small flywheel cover plate (A) at rear of bevel box and secure bolt (arrow).
24. Fit new engine/gearbox securing bolts which are accessible from above.
25. Use new bolts (1) to secure gearbox support to gearbox.
26. Pull gearbox up to gearbox support with spindle on support bracket.
27. ⚠ Before screwing in the bolts, the support arm of the gearbox mounting and the gearbox support must be aligned absolutely parallel, otherwise the threads will be damaged. If necessary, push gearbox up at the rear with trolley jack. — Use new bolts (2) to secure support arm of gearbox mounting to gearbox support.
28. ⚠ Support bracket10-222 A must not be removed until all bolts on left and right assembly mountings have been tightened to specified torque. — Remove support bracket.
29. Install subframe as follows:
30. Move drive shafts into installation position and tighten hand-tight.
31. Move subframe into installation position.
32. Fit subframe bolts.
33. Place steering box onto subframe and fit steering box bolts.
34. Secure steering box Running gear, front-wheel drive and four-wheel drive48.
35. Use new bolts to secure subframe (1)Running gear, front-wheel drive and four-wheel drive48.
36. Where fitted, secure cross piece (3) using new bolts and locking fluidD 000 600 A2 to subframe (1).
37. Bolt drive shafts to gearbox flange shafts Running gear, front-wheel drive and four-wheel drive40.
38. Install heat shield for drive shaft (right-side) (arrows).
39. Secure pendulum support to gearbox with new bolts (arrows B).
40. Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.
41. Slide propshaft onto guide pin without tilting.
42. ⚠ Make sure that the seal (arrow) in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed. — Secure pendulum support to subframe with new bolts (arrows A).
43. Bolt propshaft to flexible coupling on bevel box flange (arrows): Rear final drive 02D39.
44. Install exhaust system free of stress 26.
45. Press pressure pipe (1) into hose connector and lock in position with retaining clip.
46. ⚠ Do not press clutch pedal before clutch system has been bled. — Remove hose clamp3094.
47. Attach electrical connector for reversing light switch F4(2).
48. Install starter and fit bottom bolt. Tightening torques
49. Fit power steering pipe to gearbox (arrows).
50. Fit pressure pipe (2) to power steering pump with new seals Running gear, front-wheel drive and four-wheel drive48.
51. Remove hose clamps3094.
52. Attach electrical connector (1) for power steering pressure switch.
53. Fit power steering pump pulley and poly V-belt pulley Running gear, front-wheel drive and four-wheel drive48.
54. Install tubular cross member General body repairs, exterior50.
55. Check gear oil in manual gearbox with bevel box .
56. Install noise insulation panels General body repairs, exterior50.
57. Attach air pipe leading to charge air cooler at longitudinal member (bottom right).
58. Install top bolt securing starter. Tightening torque .
59. Attach electrical connector (3).
60. Fit bracket (2), attach wiring and engage connector in bracket.

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