Installing gearbox - vehicles with 1.9 ltr. TDI engine: Audi A3

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Renewed: if necessary

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• Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves (arrows).
• The thrust piece T10148 serves to protect the oil seal (right-side) and the gearbox from dirt.Instead of using the spindle (A), an M8 x 105 mm bolt can also be screwed hand-tight into the threaded piece in the differential.
• Carefully lift gearbox using engine and gearbox jackV.A.G 1383 A and ensure sufficient clearance between sleeve (1) and pressure plate (arrow) to prevent damage.
• Shown in illustration with gearbox removed.
• Fit air intake hose (left side). When installing air pipes with plug-in connections, make sure retaining clip (arrow) snaps onto retaining lug (A).

📋 Procedure

1. Check that dowel sleeves (A) for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.
2. Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves (arrows).
3. Check clutch release bearing for wear and renew if necessary.
4. Lubricate surface which contacts ball-head pin with grease for clutch plate splinesG 000 100.
5. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383 A.

6. Align arms of gearbox support according to holes in adjustment plate3282/39.
7. Screw support elements(A) and pin3282/29 ((C)) into adjustment plate, as illustrated.
8. Align adjustment plate3282/39 parallel to gearbox and lock safety support on gearbox.
9. Screw pin3282/29 into hole for bolt securing pendulum support to gearbox.
10. Place engine and gearbox jackV.A.G 1383 A underneath vehicle.
11. Tilt gearbox to the front by turning spindle of gearbox support3282 in direction of (arrow).
12. Remove flange shaft (right-side) (arrow) when installing a new gearbox or exchange gearbox.
13. Check flange shaft oil seals for leaks and renew if necessary .
14. Screw spindle (A) of assembly device3066 into threaded piece in differential.
15. Insert thrust piece T10148 and secure with nut (B). [Note: The thrust piece T10148 serves to protect the oil seal (right-side) and the gearbox from dirt.Instead of using the spindle (A), an M8 x 105 mm bolt can also be screwed hand-tight into the threaded piece in the differential.]
16. Carefully lift gearbox using engine and gearbox jackV.A.G 1383 A and ensure sufficient clearance between sleeve (1) and pressure plate (arrow) to prevent damage.
17. Bring gearbox into position.
18. Install bottom engine/gearbox securing bolts. Tightening torques
19. Detach gearbox support3282 with adjustment plate3282/39 from gearbox after bolting gearbox and engine together.
20. Insert cover plate (2) so that that bottom lug engages in cylinder block and secure with bolt (1). [Note: Shown in illustration with gearbox removed.]
21. Re-install flange shaft (right-side) and tighten countersunk bolt (arrow). Tightening torque
22. Fit gearbox bracket (A) with new bolts (arrows) and tighten. Tightening torque
23. Install top engine/gearbox securing bolts. Tightening torques
24. Lift engine/gearbox assembly slightly via the spindles of support bracket10 - 222 A.
25. Align engine/gearbox in installation position. To do so, raise engine/gearbox until gearbox bracket makes full contact with gearbox mounting.
26. ⚠ The threads in the gearbox bracket can be damaged if the bolts are not inserted straight.Before fitting the bolts (arrows), the gearbox bracket and the support arm of the gearbox mounting must be aligned absolutely parallel. If necessary, press rear part of gearbox up with engine and gearbox jack. — Bolt gearbox bracket onto left engine/gearbox mounting using new bolts (arrows). Tightening torque
27. ⚠ Do not remove support bracket10 - 222 A until all bolts securing the left-hand engine/gearbox mounting have been tightened to the specified torque. — Check adjustment of assembly mountings; adjust if necessary Engine, mechanics10.
28. Fit pendulum support with new bolts (1 … 3) in accordance with installation instructions . Tightening torques
29. Bolt drive shafts to flange shafts Running gear, front-wheel drive and four-wheel drive40.
30. If removed earlier, bolt on heat shield for drive shaft (right-side).
31. Attach connector (1).
32. Install strut (A). Tighten bolts (2) and (3) and secure exhaust system Engine, mechanics26.
33. Fit air intake hose (left side). When installing air pipes with plug-in connections, make sure retaining clip (arrow) snaps onto retaining lug (A).
34. Install clutch slave cylinder (arrows). Tightening torque
35. Install gearbox support (1). Tightening torque
36. Install starter Electrical system27.
37. Gearbox for vehicles with start/stop system: plug connector (arrow) into gearbox neutral position sender G701.
38. Plug in electrical connector (arrow) at reversing light switch F4.
39. Connect earth strap at upper engine/gearbox securing bolt. [Note: To install, lubricate bearings and moving surfaces with greaseG 000 450 02.]
40. If previously removed, install gearbox selector lever (A).
41. Tighten hexagon nut (arrow 4) to specified torque .
42. Insert relay lever (B) and secure with securing clip (arrow 3).
43. Attach gear selector cable to gearbox selector lever and secure with securing clip (arrow 1).
44. Attach gate selector cable to relay lever and secure with securing clip (arrow 2).
45. Insert relay lever with cable end-piece as far as stop. [Note: From 08.2008 onwards the relay lever is secured with a clip .]
46. Secure cable support bracket (arrows). Tightening torque
47. Fit bracket (B) to gearbox. Tightening torque
48. Push pipe/hose assembly (A) into bracket (B) on gearbox.
49. Adjust selector mechanism .
50. Install battery tray (arrows) and battery Electrical system27.
51. Install complete air cleaner housing 23.
52. Install engine cover panel Engine, mechanics10.
53. Install front section of wheel housing liner (left-side) General body repairs, exterior66.
54. Fit front left wheel 44.
55. Install noise insulation (centre) General body repairs, exterior50.
56. Install noise insulation frame (arrow)General body repairs, exterior50.
57. Install noise insulation (centre) (1)General body repairs, exterior50.

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