Removing and installing gear detection sensor G604 — AUDI

Removing and installing
gear detection sensor
G604
Gearbox installed
Special tools and workshop equipment required
Engine and gearbox jack
V.A.G 1383 A
Gearbox support
T10337
Torque wrench
V.A.G 1331
Removing
Remove rear noise insulation (loosen fasteners
2
and
3
).
Vehicles with diesel engine and torque reaction support
In addition, remove front noise insulation (open fasteners
1
).
Remove bolts
1
and detach torque reaction support from engine.
Note
Items marked
2
and
3
can be disregarded.
Continued for all vehicles
Note
The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.
Disconnect exhaust system at clamp
arrows
.
Using suitable wire, tie up front exhaust pipe to one side of rear section of exhaust system (at clamp).
Apply lifting column of engine and gearbox jack
V.A.G 1383 A
to gearbox from below (with
gearbox support
T10337
attached).
Slightly lift gearbox with
engine and gearbox jack
V.A.G 1383 A
.
WARNING
Risk of accident.
Engine and gearbox jack
V.A.G 1383 A
must remain in position when work is being carried out and must not be left unattended.
Remove bolts
arrows
for tunnel cross member.
Lower gearbox by dimension
a
using
engine and gearbox jack
V.A.G 1383 A
.
Dimension
a
= 80 mm (maximum)
Different connectors for
gear detection sensor
G604
Unplug electrical connector as follows:
Press catch
1
downwards and unplug connector
2
.
or
Use screwdriver to pry out catch
1
approx. 3 mm in direction of
arrow A
.
Press catch
1
downwards in direction of
arrow B
and unplug connector
2
.
Remove bolt
1
and pull out
gear detection sensor
G604
3
.
Installing
Installation is carried out in reverse sequence; note the following:
Renew O-rings
4
.
Caution
Take care when installing
gear detection sensor
G604
: risk of breakage or sensor malfunction
Gear detection sensor
G604
3
must not be knocked into the gearbox or pulled in by tightening bolt
1
.
O-rings
4
and bore in gearbox cover must be lubricated with gear oil.
Gear detection sensor
G604
3
can be pushed in carefully using a suitable tool, such as a hammer handle.
Secure
gear detection sensor
G604
with bolt
1
. Tightening torque
Anchor
Attach connector
1
and lock in place if necessary.
Secure tunnel cross member
arrows
Item
.
Vehicles with diesel engine and torque reaction support
Push torque reaction support
1
upwards in direction indicated by
arrow
until it makes contact with cross member.
Note
Bump stop
2
must be in contact with cross member without play, but must not be under tension.
Then tighten bolts
3
to specified torque
Rep. gr.
10
Assembly mountings; Exploded view - assembly mountings
.
Continued for all vehicles
Assemble exhaust system and perform stress-free alignment
Rep. gr.
26
Exhaust pipes/silencers; Exploded view - silencers
.
Install noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Exploded view - noise insulation
.
Tightening torque
Component
Nm
Gear detection sensor
G604
10 + 45°
Renew bolt