Removing gearbox (vehicles with 2.0 ltr. TDI engine) — AUDI

📋 Procedure

1. Remove engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
2. Remove air cleaner housing 23Air cleaner; Removing and installing air cleaner housing.
3. Remove starter Electrical system27Starter; Removing and installing starter
4. Remove radiator cowl 19Radiators/radiator fans; Removing and installing radiator cowl.
5. Remove subframe Running gear, axles, steering40Subframe; Removing and installing subframe with steering rack.

6. Remove flange shaft (right-side) .
7. Unbolt drive shaft (left-side) from flange shaft of gearbox Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
8. Remove securing clips (1, 2).
9. Move gear selector cable and gate selector cable clear.
10. Remove securing clip (3) and detach gate relay lever.
11. Unscrew bolts and nut (arrows), remove cable support bracket and place to one side together with cables.
12. Vehicles with plastic pipe between clutch master and slave cylinders: clamp off supply hose at brake fluid reservoir using hose clamp 3094. [Note: Clamping off the supply hose with the hose clamp3094 will cause a permanent deformation.However, this does not damage the supply hose.After removing the hose clamp 3094, the supply hose must be returned to its original shape.]
13. Place lint-free cloth under bleeder connection.
14. Pull retaining clip (arrow) out as far as stop.
15. Pull plastic pipe or pipe/hose assembly (A) out of bleeder connection.
16. Seal off open lines and connections with clean plugs from engine bung setVAS 6122. [Note: (Item B) can be disregarded.]
17. ⚠ Catch escaping brake fluid.Do not operate clutch pedal after detaching pipe/hose assembly from bleeder connection on clutch slave cylinder. — Press release tabs and disconnect crankcase breather hose (1).
18. Remove bolt (2), swivel air pipe and connection to rear and detach from turbocharger. [Note: (Item 3) can be disregarded.]
19. Vehicles with start/stop system: unplug electrical connector (4) from gearbox neutral position sender G701.
20. Unplug electrical connector (3) at reversing light switch F4. [Note: (Items 1 and 2) can be disregarded.]
21. Remove nuts (1) and bolt (3) and press electronics box (2) to one side.
22. Remove bolts (arrows).
23. Move electrical wiring and hoses clear at air pipe (left-side) using removal lever80 - 200.
24. Release hose clip (3) and detach air pipe (left-side).
25. Remove vacuum hose (arrow 1) (leading to brake servo) together with grommet (arrow 2).
26. Remove bolts (1) (accessible from above). [Note: Other items can be disregarded.]
27. Set up support bracket10 - 222 A on wing mounting flanges, as shown in illustration.
28. Engage hook of 10 - 222 A /10 in engine lifting eye (rear left).
29. Attach remaining parts of support bracket as shown in illustration.
30. Attach remaining parts of support bracket as shown in illustration.
31. Engage hook of spindle10 - 222 A /11 in engine lifting eye (front left).
32. Pre-tension hook10 - 222 A /10 and spindle10 - 222 A /11.
33. Remove bumper cover General body repairs, exterior63Bumper (front); Removing and installing bumper cover.
34. Set up support bracket10 - 222 A on top edges of body flanges (left and right) and on impact bar, as shown in illustration.
35. Attach hooks of spindles 10 - 222 A /11 to engine lifting eyes.
36. Apply light tension to spindles.
37. Remove bolts (arrows) from gearbox mounting.
38. Lower engine/gearbox assembly using spindle of support bracket10 - 222 A until distance (a) is obtained between gearbox support and gearbox mounting.
39. Remove bolts (arrows) and detach gearbox support.
40. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383 A.
41. Align arms of gearbox support according to holes in adjustment plate.
42. Bolt on support elements (A), as illustrated on adjustment plate.
43. In place of support element (C), screw in pin3282/29.
44. Place engine and gearbox jackV.A.G 1383 A underneath vehicle.
45. Align adjustment plate3282/33 parallel with gearbox.
46. Remove bolt (C) securing gearbox to engine.
47. Secure adapter VW 771/40 to threaded hole in gearbox housing, as shown in illustration.
48. Secure gearbox to gearbox support3282 with bolt M10x20 (item A).
49. Support gearbox from underneath by raising engine and gearbox jack V.A.G 1383 A.
50. Remove remaining engine/gearbox securing bolts (3, 4).
51. Press gearbox off dowel sleeves.
52. Pull gearbox off engine.
53. Lift engine slightly with spindles and push towards right side of vehicle, paying attention to refrigerant lines.
54. Carefully lower gearbox using engine and gearbox jackV.A.G 1383 A.
55. While lowering gearbox, adjust position of gearbox using spindles on gearbox support3282. [Note: When installing a replacement gearbox, the gearbox selector lever and the gate relay lever have to be transferred from the old gearbox to the new one .]

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