Removing and installing gearbox — AUDI

🧭 Before you start

Fits: platform codes 2EA, 2ED, 2EH, 2EX, 2EB, 2EE, 2EK, 2FC, 2FF, 2FL, 2FZ, 2FG, 2FM

• Opens: brake fluid, clutch fluid

Don't miss

• Mark position of propshaft in relation to propshaft flange.
• Starter remains attached to engine.
• Do not interchange selector cables during installation.Insert black selector sleeve in upper position (2).Insert white selector sleeve in lower position (3).
• To prevent brake fluid from escaping, seal the pulled-off hydraulic line using, for example, the sealing cap from the brake bleeder valve.
• Other components associated with optional equipment may be attached to the securing points for the engine support T50015 or engine support T50015A.

📋 Procedure

1. Disconnect battery 27.
2. Raise vehicle 10.2.
3. If fitted, remove noise insulation at front, centre and rear General body repairs, exterior66Exterior equipment; Noise insulation.
4. Mark position of propshaft in relation to propshaft flange.
5. Unscrew propshaft from propshaft flange (A) and attach propshaft to bodywork, e.g. using "“wire”".

6. Release securing clamp on exhaust pipe (1).
7. Remove exhaust system Power unit26Exhaust system.
8. Remove retainer (1) from exhaust system on gearbox. [Note: Do not move particulate filter, because compensator is sensitive to kinking Power unit26Exhaust system.]
9. Remove securing bolts for starter. [Note: Starter remains attached to engine.]
10. Pull gear and selector lever cable (1) out of ball heads of selector mechanism.
11. Press selector cable attachments (2) and (3) off gearbox using a screwdriver. [Note: Do not interchange selector cables during installation.Insert black selector sleeve in upper position (2).Insert white selector sleeve in lower position (3).]
12. If tachograph sender G75(2) is fitted, remove it Electrical system90Tachograph "DTCO 1381".
13. Unclip retaining clip (1) with a screwdriver from hydraulic line for hydraulic clutch release.
14. Pull off hydraulic line. [Note: To prevent brake fluid from escaping, seal the pulled-off hydraulic line using, for example, the sealing cap from the brake bleeder valve.]
15. Remove engine/gearbox connecting bolts (1) on bottom of gearbox.
16. Fit engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931 under gearbox.
17. Remove bolts (1) of gearbox carrier.
18. Lower engine and gearbox jackVAS 6931 until position for removing gearbox is achieved.
19. Install engine support T50015 or engine support T50015A. [Note: Other components associated with optional equipment may be attached to the securing points for the engine support T50015 or engine support T50015A.]
20. Turn spindle of engine support T50015 or engine support T50015A until engine is secured.
21. ⚠ It is not permitted to support the engine between the sump and the steering rack.This manner of support can lead to damage to the steering rack.As a consequence, hydraulic fluid leaks may develop in the steering rack, leading to the failure of power steering.To avoid this, use engine support T50015 or engine support T50015A to support the engine when removing the gearbox. — Unscrew and remove securing bolts from gearbox support on gearbox mounting (A).
22. Lower engine and gearbox jackVAS 6931 until gearbox carrier can be removed.
23. Raise gearbox slightly with engine and gearbox jackVAS 6931.
24. Remove remaining securing bolts (1).
25. Carefully push gearbox off engine.
26. Using tensioning strap T10038, secure gearbox on engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931.
27. Lower gearbox. [Note: All cable ties which were opened or cut during removal must be renewed at the same locations.Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline greaseG 000 100 to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.]
28. ⚠ Please observe the following points during all installation work, in particular in the engine compartment, due to the space limitations:Route all kinds of lines (e.g. for fuel, hydraulics, activated charcoal system, coolant and refrigerant, brake fluid, vacuum) and electrical cables so that the original line routing is re-established.To avoid damaging lines, make sure there is sufficient clearance from all moving or hot components. — Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary . [Note: If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.]
29. Check release bearing for wear. If necessary, renew slave cylinder with release bearing .
30. Place gearbox on engine and gearbox jackVAS 6931 and secure using tensioning strap T10038.
31. Align gearbox to engine and join.
32. Screw in bolts (1).
33. Lower engine and gearbox jackVAS 6931 until gearbox carrier can be inserted.
34. Insert gearbox carrier.
35. Screw securing bolts of gearbox support into gearbox mounting (A). [Note: Do not remove engine and gearbox jackVAS 6931 until gearbox securing bolts are tightened to specified torques.]
36. Raise gearbox again, and screw in bolts of gearbox carrier (1).
37. Bleed clutch .
38. Check selector mechanism and adjust as necessary .
39. If tachograph sender G75 was removed, install it Electrical system90Tachograph "DTCO 1381".
40. Check oil level, top up gear oil if necessary .
41. Install propshaft 39.
42. If present, install any noise insulation General body repairs, exterior66Exterior equipment; Noise insulation.
43. Connect battery 27.

Other AUDI procedures

• Removing and installing toothed belt · 56 torque figures
• Removing engine · 41 torque figures
• Removing camshaft timing chain from camshafts · 38 torque figures
• Installing engine · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing and installing gas strut for centre armrest
• Removing and installing third rear three-point seat belt (fixed rear seat backrest)
• Removing and installing front deformation element
• Removing and installing driver's knee airbag
• Removing and installing lower B-pillar trim