Removal and installation of manual transmission

GENERAL INFORMATION

The vehicle must be raised to the required height for removal. In addition, a suitable workshop lift is required to lower the transmission. This section describes in detail the removal of the manual transmission for front-wheel drive engines 1.8 L. Notes on removing the manual transmission for engines 1.6 L, as well as removal of the AT, are given at the end of the section.

Engines 1.8 L REMOVAL

PROCEDURE

1. Disconnect the negative (–) battery cable with the ignition switched off.

CAUTION

As a result, information is erased from the electronic memory modules, such as the radio code. Without the code, the radio can only be activated by the manufacturer or an AUDI service station. Therefore, refer to the sub-section Checking and replacing the alternator and voltage regulator brushes.

2. Remove the fan shroud.

3. Disconnect the tachometer sensor connector –1– and the rear fog light switch connector –2–.

4. Unscrew the mounting bolts and disconnect the damper and the manual transmission shift cable (B).

5. Disconnect the gear selector cable from the guide lever (C) by lifting the tab in the direction of the arrow.

6. Disconnect the slave cylinder hose at the cable bracket. Unscrew the mounting bolts (indicated by arrows) and disconnect the cable bracket on the manual transmission, then move it aside.

7. Unscrew the 2 mounting bolts and detach the slave cylinder from the manual transmission. Secure it to the body side with the hydraulic line still connected.

CAUTION

Do not disconnect the hydraulic line, otherwise air must be bled from the hydraulic system after installation. With the slave cylinder removed, do not press the clutch pedal.

8. Disconnect the ground cable from the upper engine-to-transmission bolt –1–. Remove bolt –1–.

9. Disconnect the cable holder –3– at the top of the starter (arrow in illustration) and move it aside.

10. Unscrew bolt –2– at the top of the starter.

11. Remove all mounting bolts between the engine and manual transmission that are accessible from above.

12. Support the engine. To do this, install a tool such as AUDI 10–222A in combination with supports 10–222A.

1.

13. Slightly raise the powertrain using the spindles.

14. If the specified tool is not available, place a pipe across the engine compartment and rest it on wooden blocks at the sides. Do not place the pipe on the fenders. Attach cables to the engine lifting eyes and connect them to the spindle. Tension the cable.

CAUTION

There is a risk involved when lifting and supporting the vehicle on stands! Therefore, first read the subsection Jacking Up the Vehicle.

15. Raise the vehicle and set it on stands. Remove the engine compartment undertray. Refer to the subsection Removing and Installing the Engine Compartment Undertray.

16. Remove the starter.

17. Unscrew the mounting bolts and remove the power steering pump line bracket from the transmission case.

18. If fitted, remove the protective cover from the right drive shaft flange (A).

19. Unscrew the mounting bolt (upper arrow) of the small cover behind the right drive shaft and remove the cover.

20. Unscrew the drive shaft mounting bolts and disconnect the drive shafts. Refer to the subsection Removing and Installing Drive Shafts.

21. Suspend the drive shafts as high as possible on wire. To do this, turn the steering wheel fully to the left.

CAUTION

Do not damage the paint finish.

22. Disconnect the exhaust system between the catalytic converter and the center muffler. Refer to the subsection Replacing the Center/Auxiliary Muffler.

23. Unscrew the mounting bolts and disconnect the pendulum support between the body and the engine/transmission side (arrow in illustration).

24. Unscrew the mounting bolts and disconnect the left transmission mount rod (arrow A in illustration), then disconnect the transmission mount (arrow B in illustration).

25. Unscrew the mounting bolts of the transmission mount (A) on the transmission and disconnect it. To remove the mounting bolts (indicated by arrows), lower the engine-transmission unit using the spindles so that the bolts are accessible from the left wheel arch.

CAUTION

When lowering the unit, make sure not to damage the power steering lines.

26. Secure the special tool (C) with bolt (B) at the underside of the pendulum support mount. Insert the press-off tool (A) and secure it with bolts (indicated by arrows). Press the engine-transmission unit forward.

CAUTION

If the special tool is not available, the engine-transmission unit can be moved forward with a bottle jack. Make sure not to damage the power steering lines.

27. Slightly raise the manual transmission using a jack, such as AUDI

3282. Before installation, align the transmission mount brackets using alignment plate 3282.

8. If a transmission jack is not available, raise the manual transmission with a workshop floor jack.

CAUTION

Place a wooden spacer between the manual transmission and the jack.

28. Unscrew the lower mounting bolts between the engine and the manual transmission.

29. Press the manual transmission off the guide bushings and carefully pull it out.

CAUTION

When removing the manual transmission, take care not to damage the power steering line.

INSTALLATION

CAUTION

If the manual transmission is being replaced, transfer the speedometer sensor, shift lever and selector lever from the old transmission to the new one.

30. Before installing the clutch, inspect it. Refer to the subsection Removing, Installing and Checking the Clutch.

31. Clean the input shaft of the manual transmission and lightly lubricate it with MoS2 grease or AUDI–G 000 100.

CAUTION

The clutch disc must slide freely on the shaft.

32. Check whether guide bushings for centering the engine/transmission unit are installed in the cylinder block. If necessary, insert them.

33. Before installing the manual transmission to the transmission case, press the clutch release lever and secure it with an assembly bolt or an M8 x

35. Remove the bolt after installation.

34. Raise the manual transmission and engage its clutch. If the input shaft does not enter the clutch disc, turn the input shaft by hand at the rear flange. When installing, make sure the intermediate plate is correctly positioned.

35. Turn and remove the special tool or jack.

36. Install the manual transmission and starter mounting bolts. To do this, install the starter.

37. Insert the engine/transmission unit mounting bolts as deep as possible.

38. Unscrew the M8 x 35 bolt again to secure the clutch release lever on the clutch housing. The hole is covered by the bolt securing the shift linkage support bracket.

39. Loosely tighten the left transmission mount bracket and position the engine/transmission assembly with the crane.

40. Loosely tighten the engine/transmission support with new bolts (B).

41. Loosely tighten the torque strut with new bolts.

42. Remove the engine and transmission lifting device.

43. Align the engine/transmission assembly by rocking it firmly from side to side.

44. Tighten the engine/transmission assembly and torque strut to the values given in the Specifications. Tighten the bolts first with a torque wrench, then turn them an additional 90° (1/4 turn) with a standard wrench.

CAUTION

Bolts undergo permanent deformation when tightened. For this reason, always use new bolts each time they are loosened.

45. Install the drive shafts. Refer to Drive Shafts Removal and Installation.

46. Install the large and small drive shaft covers.

47. Install the left engine mount bracket bolts and tighten to 50 N·m (see illustration for transmission mounting bolt locations and tightening torques).

48. Install the starter motor.

49. Secure the selector cable bracket to the transmission with bolts. Tighten to 25 N·m.

50. Secure the shift cable to the shift lever. Tighten to 25 N·m.

51. Connect the selector cable to the shift lever.

52. Install the counterweight on the shift lever. Tighten the bolts first with a torque wrench to 20 N·m, then turn an additional 90° (1/4 turn) with a standard wrench.

53. Adjust the shift linkage. Refer to Shift Linkage Adjustment.

54. Connect the connector at the transmission. Refer to Removal.

55. Connect the starter connector.

56. Lubricate the end of the hydraulic slave cylinder pushrod with MoS2 grease.

2. Install the slave cylinder in place and tighten to 20 N·m.

57. Depress the clutch pedal several times and check operation.

CAUTION

If the hydraulic system has been opened, bleed air from the system.

58. Install the front pipe/catalytic converter with new gaskets. Refer to Exhaust System Removal and Installation.

59. Secure the power steering fluid line bracket to the transmission case. Refer to Power Steering Pump Removal and Installation.

60. Check the transmission fluid level. Refer to Transmission Fluid Level Check.

61. Install the engine compartment lower cover. Refer to Engine Compartment Lower Cover Removal and Installation.

62. Install the air filter housing. Refer to Air Filter Housing Removal and Installation.

63. Connect the negative (–) battery cable to the battery.

CAUTION

Activate the anti-trap function of the power windows, enter the radio code and set the clock. Refer to the subsection Radio Code Entry.

Specifically for 1.6 L engines

CAUTION

The description of work and notes applying to all manual transmissions are given in the subsection for engines 1.8 L. This subsection describes only the differences relating solely to engine 1.6 L. These differences concern mainly the shift operation, which for engine 1.6 L is performed via rods, while on other engines it is performed via cables.

64. Support the engine with the crane, hooking it to the lifting eyes on the cylinder head.

65. Using a screwdriver, disconnect front link –1– from lever –2–. Remove lock washer –3–, remove bracket –4–.

66. Disconnect bracket –4– from damper link –5– by turning it 90° (1/4 turn) to the right. Tilt the damper link upward and remove it from bearing support –6–.

67. Using a screwdriver, disconnect the long connecting rods from the gear selector lever (as indicated by arrows). Unscrew the bolt and disconnect the front shift lever –1– at the transmission.

68. Unscrew bolts –2– and remove shift linkage bracket –3– together with the connecting rods and shift lever.

69. Disconnect the slave cylinder hose at the support. Unscrew the 2 mounting bolts and disconnect the slave cylinder (as indicated by arrows) at the transmission, then secure it to the body with wire, with the hose still connected.

CAUTION

Do not disconnect the hydraulic line, otherwise the clutch will need to be bled after installation. Do not depress the clutch pedal after removing the slave cylinder. After installing the manual transmission, adjust the shift linkage. Refer to the subsection Dismantling the Drive Shaft.