Service

Workshop Manual
Audi A3 2004 ➤
Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4
Edition 02.2011

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt A0050306420

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 12
2.1 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 12
3 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Exploded view - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Removing and installing pipe/hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Exploded view - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Overview - servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Clutch identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2 Exploded view - Sachs version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8.3 permitted
Removing andbyinstalling
unless authorised AUDI AG. AUDIclutch
AG does(Sachs version)
not guarantee or accept. any
. . liability
............................... 47
8.4 withExploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by AUDI AG.
50
8.5 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Exploded view - gear knob and gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.3 Separating gear lever boot from gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.4 Exploded view - gear lever and selector housing on vehicles up to model year 2007 . . . . 59
1.5 Exploded view - selector mechanism on vehicles from model year 2008 onwards . . . . . . 62
1.6 Dismantling and assembling selector mechanism on vehicles from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.8 Exploded view - gear selector cable and gate selector cable up to model year 2007 . . . . 72
1.9 Exploded view - gear selector cable and gate selector cable from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 81
1.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine . . . . . . . . . . . . . . . . . . 86
2.1 Removing gearbox - vehicles with 1.6 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.2 Installing gearbox - vehicles with 1.6 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3 Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine . . . . . . . . . . . . . . . . . . 101
3.1 Removing gearbox - vehicles with 1.9 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Contents i
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3.2 Installing gearbox - vehicles with 1.9 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.3 Removing and installing gearbox bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6 Checking gear oil level and filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.2 Draining off gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3 Filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3 Exploded view - removing and installing gearbox housing cover and 5th gear . . . . . . . . . . 137
7.4 Exploded view - removing and installing gearbox housing and selector mechanism . . . . . . 139
7.5 Exploded view - removing and installing input shaft, output shaft, differential and selector
forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.6 Assembly sequence - removing and installing gearbox housing cover and 5th gear . . . . . . 141
8 Assembly sequence - dismantling and assembling complete gearbox . . . . . . . . . . . . . . . . 147
8.1 Dismantling complete gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.2 Assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9 Exploded view - servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . 162
10 Removing and installing gearbox neutral position sender G701 . . . . . . . . . . . . . . . . . . . . 169
11 Exploded view - servicing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
11.1 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
11.2 Dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
12 Exploded view - dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . 175

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.1 Exploded view - dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.1 Exploded view - dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Exploded view - dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . 210

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1 Renewing oil seals for flange shafts with gearbox installed in vehicle . . . . . . . . . . . . . . . . 213
1.1 Renewing oil seal for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.2 Identification of flange shaft oil seals (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.3 Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve . . . . . . . . . . . . 216
1.4 Renewing oil seal together with sleeve (one-piece sleeve and oil seal for flange shaft (right-
Protected byside)) . . . . .for. .private
copyright. Copying . . . or
. .commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. .not. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2with respect
Table
to the of adjustments
correctness of information. in
. this
. . .document.
. . . . . Copyright
. . . . . .by. AUDI. . . AG.
.................................. 226
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.1 Exploded view - dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

ii Contents
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

00 – Technical data
1 Gearbox identification
The 5-speed manual gearbox 0A4 is installed in the Audi A3 2004
► and the Audi A3 Cabriolet 2008 ►.
• ⇒ „1.1 Code letters, allocation, transmission ratios, capaci‐
ties“, page 1
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 0A4 -arrow 2-

Manual gearbox 0A4 -arrow 2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Code letters and date of manufacture of gearbox

Example: FNE 03 06 3
I I I I
Code letters Day Month Year (2003) of
manufacture
Additional data are manufacture-related.

Note

The code letters for the gearbox are also given on the vehicle data
stickers.

1.1 Code letters, allocation, transmission ra‐

tios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Individual gear ratios
♦ Gear oil specification
♦ Allocation of flange shafts

1. Gearbox identification 1
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Allocation of clutch type

Manual gearbox 5-speed 0A4
Code letters FNE GQQ HGN
Manufactured from 04.03 07.03 06.06
to 07.03 06.06 07.06
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008
►
Engine 1.9 ltr. - 77 kW TDI 1.9 ltr. - 77 kW TDI 1.9 ltr. - 77 kW TDI
Ratio Final drive 61 : 18 = 3.389 61 : 18 = 3.389 61 : 18 = 3.389
Z1 : Z2
Capacity of manual gearbox 1.9 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.7 ltr.
⇒ page 132 (gearbox partially
dismantled)

Manual gearbox 5-speed 0A4

Code letters JCR KBL LHW
Manufactured from 06.06 03.07 05.09
to 05.10 05.10 06.09
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008
►
Engine 1.9 ltr. - 77 kW TDI 1.9 ltr. - 77 kW TDI 1.6 ltr. - 66 kW TDI
Ratio Final drive 61 : 18 = 3.389 61 : 18 = 3.389 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox 1.9 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.7 ltr.
⇒ page 132 (gearbox partially
dismantled)

Manual gearbox 5-speed 0A4

Code letters LUB MDZ
Manufactured from 05.09 01.10
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to with respect to the correctness of information in this document. Copyright by AUDI AG.

Allocation Model
Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008
►
Engine 1.6 ltr. - 77 kW TDI 1.6 ltr. - 77 kW TDI
Ratio Final drive 62 : 17 = 3.647 61 : 18 = 3.778
Z1 : Z2
Capacity of manual gearbox 1.9 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.7 ltr.
⇒ page 132 (gearbox partially
dismantled)

2 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

2 Transmission layout

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Output shaft
6 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Transmission layout 3
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3 Calculating ratio „i“

Example:
5th gear Final drive
Drive gear ZG1 = 39 ZA1 = 18
Driven gear ZG2 = 29 ZA2 = 61

i = Z2 : Z1 1)
iG = gear ratio = ZG2 : ZG1 = 29 : 39 = 0.744
iA = axle ratio = ZA2 : ZA1 = 61 : 18 = 3.389
iov = overall ratio

iov = iG x iA = 0.744 x 3.389 = 2.520

1) Z1 = No. of teeth on drive gear, Z2 = No. of teeth on driven gear

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

4 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools
♦ For a complete list of special tools used in this Workshop
Manual ⇒ Workshop equipment and special tools .
Gearbox
♦ Allocate bolts and other components according to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of
wax and grease.
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ For gear oil specification, refer to ⇒ Electronic parts cata‐
logue .
♦ Gear oil must be filled up as required after repairing the gear‐
box.
Capacity (gearbox completely Capacity (gearbox partially
dismantled) dismantled) ⇒ page 132
1.9 ltr. 1.7 ltr.
Sealants Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Thoroughly clean housing contact surfaces before applying
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

sealing paste .
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Apply sealing paste -AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste .

4. General repair instructions 5

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Oil seals, seals, O-rings and gaskets

♦ Always renew oil seals, O-rings and gaskets.
♦ After removing gaskets and oil seals, always inspect the con‐
tact surface on the housing or shaft for burrs resulting from
removal or for other signs of damage.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease -G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ Check oil level after installing new gaskets, O-rings and oil
seals ⇒ page 132 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Locking elements with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Do not over-stretch circlips.

♦ Installation position for some circlips: the circlip is fitted so that
the narrow part of the gap is at the top. This also gives the
pliers a better grip when removing and installing.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.

6 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ Always renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then apply locking fluid -
AMV 185 101 A1- to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a thread tap or sim‐
ilar). Otherwise there is a danger of the bolts shearing off the
next time they are removed.
♦ For all threaded connections,
Protected ensure that
by copyright. (where
Copying applicable)
for private or commercial purposes, in part or in whole, is not
the contact surfaces andpermitted
the nuts and bolts are not coated with
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

wax until after assembly is completed.

with respect to the correctness of information in this document. Copyright by AUDI AG.

Bearings
♦ Lubricate all bearings in gearbox housing with gear oil before
installing.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Do not interchange the outer or inner races of bearings of the
same size (the bearings are paired).
♦ If required, renew the tapered roller bearings on one shaft to‐
gether and use new bearings from a single manufacturer.
♦ Install needle bearings, ball sleeves and roller bearings so the
lettering (side with thicker metal) faces towards the installing
tool.

Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only shims which are in perfect condition.
Synchro-rings

4. General repair instructions 7

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Do not interchange synchro-rings. When reusing always fit to

the same selector gear.
♦ Check for wear; renew if necessary.
♦ Check the grooves -arrow 1- on synchro-ring -A- and on inner
ring for wear (flattened sections in grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is fitted, check the outer contact
surface -arrow 2- and inner contact surface -arrow 3- of the
intermediate ring for »scoring«, »visible traces of wear« and
»blue discolouration (caused by overheating)«.
♦ Check chamfer on selector gear for scoring and visible traces
of wear.
♦ Lubricate synchro rings with gear oil before installing.
Gear wheels
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Clean before pressing on. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Use inductive heater -VAS 6414- to heat to approx. 100°C be‐
fore installing. Press home onto stop when installing so there
is no axial clearance.
♦ Note correct installation position.
Selector gears and locking collars
♦ After installing, check 1st to 5th selector gears for minimal axial
play and freedom of movement.

♦ Abnormal wear on synchro-ring or selector gear:

A - Worn chamfer on dog teeth of synchro-ring or selector gear.

♦ In comparison: intact synchro-ring or selector gear:

B - Intact chamfer on dog teeth of synchro-ring or selector gear.

8 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Abnormal wear on locking collar:

C - Worn chamfer on internal splines of locking collar.

♦ In comparison: intact locking collar:

D - Intact chamfer on internal splines of locking collar.
Clutch actuation
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the clutch slave
cylinder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the clutch slave cylinder.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures
⇒ „2 Notes on removing and installing clutch master cylinder
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

and slave cylinder“, pageto12the ).

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect correctness of information in this document. Copyright by AUDI AG.

♦ Keep clutch pressure plate straight when removing and instal‐

ling
♦ If the clutch has burnt out, thoroughly clean the clutch housing,
flywheel and parts of the engine facing the gearbox in order to
prevent odour.
♦ Only blow out dual-mass flywheel with compressed air.

4. General repair instructions 9

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

5 Safety precautions for vehicles with

start/stop system

WARNING

Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

30 – Clutch
1 Overview - clutch mechanism

Note

If you suspect a defective clutch master cylinder or clutch slave cylinder, pay attention to
⇒ „2 Notes on removing and installing clutch master cylinder and slave cylinder“, page 12 and perform
⇒ „2.1 Function check for clutch master cylinder and slave cylinder“, page 12 prior to renewing.

I-
⇒ „3 Exploded view - pedal
cluster, clutch master cylin‐
der“, page 14
❑ ⇒ „3.1 Removing and in‐
stalling over-centre
spring“, page 15
❑ ⇒ „3.2 Removing and in‐
stalling clutch pedal“,
page 17
❑ ⇒ „3.3 Removing and in‐
stalling mounting brack‐
et“, page 20
❑ ⇒ „3.4 Removing and in‐
stalling clutch position
sender G476 “,
page 23
❑ ⇒ „3.5 Removing and in‐
stalling clutch master
cylinder“, page 25
II -
⇒ „4 Exploded view - hydraul‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ics (LHD)“, page 27 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ ⇒ „4.1 Removing and in‐
stalling clutch slave cyl‐
inder“, page 29
❑ ⇒ „4.2 Removing and in‐
stalling pipe/hose as‐
sembly“, page 34
❑ ⇒ „6 Bleeding clutch
system“, page 39
III -
⇒ „5 Exploded view - hydraul‐
ics (RHD)“, page 37

1. Overview - clutch mechanism 11

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

2 Notes on removing and installing

clutch master cylinder and slave cyl‐
inder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective, you must first carry out
the appropriate function check
⇒ „2.1 Function check for clutch master cylinder and slave
cylinder“, page 12 .
♦ If the slave cylinder is removed from gearbox with the pipe/
hose assembly still attached, make sure you do not press the
clutch pedal. Otherwise, the piston will be pressed out of the
slave cylinder and be destroyed.
♦ After installing the slave cylinder, carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. The plunger of the slave cylinder is likely to have been
guided past the clutch release lever. The slave cylinder would
then be destroyed once pedal force exceeds approx. 300 N.

2.1 Function check for clutch master cylin‐

der and slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The vent opening must be uncovered, otherwise the toperma‐
with respect the correctness of information in this document. Copyright by AUDI AG.
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of the clutch system can be im‐
paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).

12 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 39 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
High pedal force:
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 44 .
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 39 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.).
♦ Foreign body in clutch system.
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 44 .
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel
sleeves).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Notes on removing and installing clutch master cylinder and slave cylinder 13
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3 Exploded view - pedal cluster, clutch master cylinder

1 - Bulkhead
❑ With mounting for
mounting bracket
2 - Seal
❑ Renew
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond onto mounting
bracket
3 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing
⇒ page 20
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 15
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 17
9 - Retaining clip
❑ For operating rod on
clutch master cylinder
10 - Seal
❑ Renew
❑ Between master cylin‐
der and mounting brack‐
et
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 25
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 23
❑ Can be checked in „Guided fault finding“ using ⇒ vehicle diagnostic tester
13 - Retaining clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Supply hose
❑ To brake fluid reservoir
❑ Made of rubber or plastic, depending on version
❑ Plastic supply hose with additional seals ⇒ page 28
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Nut permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For securing mounting bracket to bulkhead
❑ 20 Nm
❑ 3x

14 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

❑ Self-locking
❑ Renew
16 - Nut
❑ 25 Nm
❑ Self-locking
❑ Renew
17 - Stop
❑ For clutch pedal

Crash bar - tightening torque

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

The crash bar -2- is not fitted on earlier versions.

– Install crash bar -2- and tighten 1 or 2 bolts (depending on

version) -arrows B-.
• M6 - 10 Nm
• M8 - 20 Nm

3.1 Removing and installing over-centre

spring
Special tools and workshop equipment required
♦ Assembly tool -T10178-

♦ Grease -G 000 450 02-

3. Exploded view - pedal cluster, clutch master cylinder 15

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .
– Unscrew bolt -arrow A- and remove footwell vent (front left)
-1-.
– Unclip wiring harness at rear of footwell vent -1- and move
clear to one side.
– If fitted, unbolt crash bar -2- (secured by one or two bolts
-arrows B-, depending on version).

– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,

remove nut -2- and pull out bolt -5-.

Note

The clutch pedal does not have to be detached from the operating
rod on the clutch master cylinder.

– Pivot clutch pedal down slightly and and take over-centre

spring -4- out of mounting bracket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
Installation is carried out in reverse sequence; note the following:

Note

♦ Renew self-locking nut.

♦ Lubricate all bearings and contact surfaces with grease -G 000
450 02- .

– Fit over-centre spring -2- into mounting bracket from above

while holding end of spring in correct position with assembly
tool -T10178- .

16 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

• Socket -arrow- of over-centre spring must be in vertical posi‐

tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press clutch pedal slightly, push bolt through and tighten self-
locking nut. Tightening torque ⇒ Item 16 (page 15)
– If fitted, install crash bar ⇒ page 15 .
– Install footwell vent (front left) ⇒ Heating, air conditioning;
Rep. gr. 80 .
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

3.2 Removing and installing clutch pedal

Special tools and workshop equipment required
♦ Pliers -T10005-

♦ Assembly tool -T10178-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ unless
permitted Grease -G 000
authorised 450
by AUDI AG.02-
AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Exploded view - pedal cluster, clutch master cylinder 17

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. gr. 68 .
– Unscrew bolt -arrow A- and remove footwell vent (front left)
-1-.
– Unclip wiring harness at rear of footwell vent -1- and move
clear to one side.
– If fitted, unbolt crash bar -2- (secured by one or two bolts
-arrows B-, depending on version).

– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,

remove nut -2- and pull out bolt -5-.
– Pivot clutch pedal forward slightly and and take over-centre
spring -4- out of mounting bracket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release retaining clip for operating rod on clutch master cyl‐

inder using pliers -T10005- .
– Remove clutch pedal.

18 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing
Installation is carried out in reverse sequence; note the following:
• Tightening torque ⇒ page 14

Note

♦ Renew self-locking nut.

♦ Lubricate all bearings and contact surfaces with grease -G 000
450 02- .

– Install retaining clip -2- on operating rod -1- of master cylinder.

– Press retaining clip into mounting on clutch pedal so that it
snaps into place.

– Fit over-centre spring -2- into mounting bracket from above

while holding end of spring in correct position with assembly
tool -T10178- .

• Socket -arrow- of over-centre spring must be in vertical posi‐

tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press top of clutch pedal forwards against spring pressure of
over-centre spring, push through bolt and tighten self-locking
nut.

Note

It is easier to press the clutch pedal against the spring if you pull
back the bottom of the pedal carefully as you bring the top of the
pedal into installation position.

– If fitted, install crash bar ⇒ page 15 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install footwellpermitted
vent (front left) ⇒ byHeating,
unless authorised air conditioning;
AUDI AG. AUDI AG does not guarantee or accept any liability
Rep. gr. 80 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

3. Exploded view - pedal cluster, clutch master cylinder 19

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3.3 Removing and installing mounting

bracket
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm -3094-

♦ Hose clip pliers -VAS 6340-

Removing
– Move driver's seat away from pedals.

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– With ignition switched off, disconnect earth wire -arrow- at

battery.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove air cleaner housing completely ⇒ copyright.

Protected by Rep. gr. 23for. private or commercial purposes, in part or in whole, is not
Copying
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

20 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove battery tray -arrows- (detach front of battery tray from

air duct if applicable).

Note

In the following steps make sure that no brake fluid escapes onto
the longitudinal member or onto the gearbox below. If this does
happen, clean the affected area thoroughly.

– Using hose clamp up to 25 mm -3094- , clamp off supply hose

to clutch master cylinder.

– Disconnect supply hose at clutch master cylinder (if necessa‐

ry, release spring-type clip -3- using hose clip pliers -VAS
6340- ).
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -1- or plastic pipe from clutch master cyl‐
inder.
– Unclip and detach clutch position sender -G476- from clutch
master cylinder -arrow-. Electrical connector -4- can remain
connected.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Exploded view - pedal cluster, clutch master cylinder 21

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove storage compartment on driver's side ⇒ General

body repairs, interior; Rep. gr. 68 .
– Unscrew bolt -arrow A- and remove footwell vent (front left)
-1- ⇒ Heating, air conditioning; Rep. gr. 80 .
– Unclip wiring harness at rear of footwell vent -1- and move
clear to one side.
– If fitted, unbolt crash bar -2- (secured by one or two bolts
-arrows B-, depending on version).

Note

When working in the footwell, put cloths on the floor covering to

protect it from possible brake fluid spills.

– Remove nuts -2-.

– Take out mounting bracket -1-.
Installing
Installation is carried out in reverse sequence; note the following:
• Tightening torque ⇒ page 14

Note

♦ Renew self-locking nuts.

♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .

– Fit mounting bracket -1- and tighten nuts -2-.

– Install pipe/hose assembly or plastic pipe ⇒ page 34 .
– Bleed clutch system ⇒ page 39 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– If fitted, install crash bar ⇒ page
permitted 15 . by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install footwell vent (front left) ⇒ Heating, air conditioning;
Rep. gr. 80 .
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

22 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3.4 Removing and installing clutch position

sender -G476-
Removing
– Detach cover above battery (press release tab -arrow-).

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– With ignition switched off, disconnect battery earth strap

-arrow-.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove complete air cleaner housing ⇒ Rep. gr. 23 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Exploded view - pedal cluster, clutch master cylinder 23

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove battery tray -arrows-.

– Unplug electrical connector -4-.

– Unclip clutch position sender -G476- at clutch master cylinder
in direction of -arrow- and remove.

Note

Items -1 … 3- can be disregarded.

Installing
Perform installation in reverse sequence of removal.
– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.

Note

Items -1 … 3- can be disregarded.

– Install battery tray and battery ⇒ Electrical system; Rep. gr.

27 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install air cleaner
permittedhousing ⇒ Rep.
unless authorised gr.AG.23
by AUDI . AG does not guarantee or accept any liability
AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.

24 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3.5 Removing and installing clutch master

cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-

Removing

Note

♦ If you suspect a defective clutch master cylinder, perform

function test prior to renewing
⇒ „2 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 12 .
♦ When working in the footwell, put cloths on the floor covering
to protect it from possible brake fluid spills.

– Remove mounting bracket ⇒ page 20 .

– Release retaining clip for operating rod on clutch master cyl‐
inder using pliers -T10005- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Insert a spacer -A- between
permitted clutch by
unless authorised pedal
AUDI AG.andAUDI
stop, andnotpress
AG does guarantee or accept any liability
clutch pedal forward.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Length of spacer = approx. 40 mm (e.g. 1/2" socket).

– Release retainer clip -B- and pull master cylinder out of mount‐
ing bracket -arrow 1- and -arrow 2-.

3. Exploded view - pedal cluster, clutch master cylinder 25

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing
• Clutch pedal in „released“ position.
– Install retaining clip -2- on operating rod -1- for clutch master
cylinder.

– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Length of spacer = approx. 40 mm
with respect to the (e.g. 1/ "of socket).
2 information in this document. Copyright by AUDI AG.
correctness

– Secure master cylinder on mounting bracket -arrow 1- and

-arrow 2-.

– Press operating rod -1- for master cylinder in direction of

-arrow- so that retaining clip -2- snaps into place in clutch ped‐
al.
– Install mounting bracket ⇒ page 20 .

26 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

4 Exploded view - hydraulics (LHD)

1 - Brake fluid reservoir

2 - Hose clip (spring-type clip)
❑ Not fitted in all vehicles
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐
sion
❑ Plastic supply hose with
additional seals
⇒ page 28
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 25
5 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
6 - Retaining clip
❑ To remove and install
retaining clip first detach
clutch master cylinder
from clutch pedal
⇒ page 17
7 - Clutch pedal
❑ Removing and installing
⇒ page 17
8 - Nut
❑ For securing mounting
bracket to bulkhead
❑ Tightening torque Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 15 (page 14) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
10 - Pipe/hose assembly
❑ With frequency modulator on some versions
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ page 34
❑ Disconnecting from clutch master cylinder and clutch slave cylinder ⇒ page 29
11 - Bracket
❑ For pipe/hose assembly ⇒ Item 10 (page 27)
❑ Secured on body
12 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue

4. Exploded view - hydraulics (LHD) 27

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

❑ Renew damaged seals or O-rings

❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
13 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Clutch slave cylinder
❑ Removing and installing ⇒ page 29
15 - Bolt
❑ 20 Nm
❑ 2x
16 - Bleeder valve
❑ 6 Nm
❑ Bleeding clutch system ⇒ page 39
17 - Dust cap
18 - Gearbox
19 - Bracket
❑ For pipe/hose assembly
20 - Bolt
❑ 20 Nm

O-rings or seals for pipe/hose assemblies

Item Type of connection
1 Connection with annular groove -arrow 1-
2 Connection with shoulder -arrow 2-
3 Connection with shoulder -arrow 2- and annular
groove -arrow 3-
• Connection with annular groove -arrow 1- and -arrow 3-: seal
or O-ring must be inserted in groove.

Vehicles with plastic supply hose -1-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Seals -2- must be fitted in supply hose. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

28 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Disconnecting and connecting hose/pipe assembly from/to clutch

master cylinder/clutch slave cylinder
– To remove, release clip -3- with a screwdriver and disconnect
pipe/hose assembly -1- from clutch master cylinder/slave cyl‐
inder -4-.
Installing

Note

♦ Observe distinction between seals -2- and O-rings

⇒ page 28 .
♦ Renew damaged seals or O-rings.

– Press pipe/hose assembly -1- onto connection on clutch slave

cylinder and clutch master cylinder -4- so that clip -3- snaps
into place.
– Pull on pipe to check it is secure.

4.1 Removing and installing clutch slave

cylinder
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm -3094-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing

Note

♦ If you suspect a defective clutch slave cylinder, perform func‐

tion test prior to renewing
⇒ „2 Notes on removing and installing clutch master cylinder
and slave cylinder“, page 12 .
♦ If the slave cylinder is removed from gearbox with the pipe/
hose assembly still attached, make sure you do not press the
clutch pedal. Otherwise, the piston will be pressed out of the
slave cylinder and be destroyed.

4. Exploded view - hydraulics (LHD) 29

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Detach cover above battery (press release tab -arrow-).

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– With ignition switched off, disconnect battery earth strap

-arrow-.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove complete air cleaner housing ⇒ Rep. gr. 23 .

– Remove battery tray -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

30 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Metal relay lever -B-:

– Detach securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
– Detach securing clip -arrow 2- for gate selector cable from re‐
lay lever -B-.
– Pull both cables off pins.

Note

Arrows -3 … 4- can be disregarded.

Plastic relay lever with detent -arrow 2-

– Detach securing clip -arrow 1- and pull gear selector cable off
gearbox selector lever -A-.
– Detach gate selector cable from cable end-piece
⇒ page 88 .
– Press detent -arrow 2- down onto stop and remove relay lever
together with cable end-piece. Move relay lever in normal di‐
rection of operation.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

-Arrow 3- can be disregarded.

Plastic relay lever with clip -arrow 1-

– Pull out clip -arrow 1- and remove relay lever together with
cable end-piece -arrow 2-.
Continued for all vehicles:
– Tie back gear selector cable and gate selector cable.

4. Exploded view - hydraulics (LHD) 31

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove gearbox support -arrows-.

– Unclip pipe/hose assembly from bracket -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove boltspermitted
-1- and -2-authorised
unless and detach clutch
by AUDI AG. AUDI slave
AG doescylinder.
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Make sure that no brake fluid escapes onto the gearbox. If this
does happen, clean the affected area thoroughly.

– Place a lint-free cloth under the clutch slave cylinder.

– Using hose clamp -3094- , clamp off pipe/hose assembly go‐
ing to clutch slave cylinder.
– Pull out clip -1- as far as it will go, move pipe/hose assembly
-2- clear at bracket and disconnect from clutch slave cylinder.

Caution

Do not operate clutch pedal after disconnecting pipe/hose as‐

sembly.

Installing
Installation is carried out in reverse sequence; note the following:
– Connect pipe/hose assembly to clutch slave cylinder
⇒ page 29 .
– Lubricate end of plunger with grease for clutch plate splines -
G 000 100- .
– Install clutch slave cylinder and tighten bolts -1- and -2-. Tight‐
ening torque ⇒ Item 15 (page 28)
– Clip pipe/hose assembly into bracket -arrow-.
– Remove hose clamp -3094- .

32 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Fit gearbox support and tighten bolts -arrows-. Tightening tor‐

ques ⇒ Item 1 (page 122)
– Bleed clutch system ⇒ page 39 .

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

Metal relay lever -B-:

– Attach gear selector cable to gearbox selector lever -A- and
secure with securing clip -arrow 1-.
– Attach gate selector cable to relay lever -B- and secure with
securing clip -arrow 2-.

Note

Arrows -3 … 4- can be disregarded.

Plastic relay lever with detent -arrow 1-:

– Insert relay lever with cable end-piece as far as stop.
• Relay lever is secured by detent -arrow 1-.
• Cable end-piece is secured by detent -arrow 2-. by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Ensure that components engage securely. with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Exploded view - hydraulics (LHD) 33

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Plastic relay lever with clip -arrow 1-

– Fit relay lever and secure with clip -arrow 1-.
Continued for all vehicles:
– Check gear lever setting ⇒ page 85 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

4.2 Removing and installing pipe/hose as‐

sembly
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm -3094-

Removing
– Remove air cleaner housing completely ⇒ Rep. gr. 23 .

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery ⇒ Electrical system; Rep. gr. 27 .

– Remove battery ⇒ Electrical system; Rep. gr. 27 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

34 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove battery tray -arrows-.

Note

♦ In the following steps make sure that no brake fluid escapes

onto the longitudinal member or onto the gearbox below. If this
does happen, clean the affected area thoroughly.
♦ Place a cloth underneath to catch escaping brake fluid.

– Use hose clamp -3094- to clamp off supply hose to clutch

master cylinder.

– Unclip pipe/hose assembly -2- from bracket -1-.

Note

-Item 3- can be disregarded.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Exploded view - hydraulics (LHD) 35

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Note

Make sure that no brake fluid escapes onto the gearbox. If this
does happen, clean the affected area thoroughly.

– Release clip -3- with a screwdriver and disconnect pipe/hose

assembly -1- from clutch master cylinder and clutch slave cyl‐
inder.
– Detach pipe/hose assembly -1- from bracket and remove.

Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Do not operate clutch pedal after disconnecting pipe/hose as‐

with respect to the correctness of information in this document. Copyright by AUDI AG.

sembly.

Installing
Installation is carried out in reverse sequence; note the following:

Note

♦ Observe distinction between seals -2- and O-rings

⇒ page 28 .
♦ Renew damaged seals or O-rings.

– Press pipe/hose assembly -1- onto connection on clutch slave

cylinder and clutch master cylinder -4- so that clip -3- snaps
into place.
– Pull on pipe to check it is secure.

– Clip pipe/hose assembly -2- onto bracket -1-.

– Remove hose clamp -3094- .
– Bleed clutch system ⇒ page 39 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

36 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

5 Exploded view - hydraulics (RHD)

1 - Brake fluid reservoir

2 - Seal
❑ For plastic supply hose
❑ Seals must be fitted in
supply hose
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐
sion
❑ Plastic supply hose with
additional seals
⇒ Item 2 (page 37)
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 25
5 - Clip
❑ To remove and install
pipe, pull out clip as far
as it will go
6 - Seal or O-ring
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Whether
permitted a seal or
unless authorised an O-
by AUDI AG. AUDI AG does not guarantee or accept any liability
ring
with is used
respect dependsof on
to the correctness information in this document. Copyright by AUDI AG.
the type of connection
⇒ page 28
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
7 - Retaining clip
❑ To remove and install retaining clip first detach clutch master cylinder from clutch pedal ⇒ page 17
8 - Clutch pedal
9 - Nut
❑ 20 Nm
❑ For securing mounting bracket to bulkhead
10 - Bracket
❑ Secured on body
11 - Pipe
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ To remove, first remove battery and battery tray ⇒ Electrical system; Rep. gr. 27
12 - Seal or O-ring
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 28

5. Exploded view - hydraulics (RHD) 37

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

❑ For correct version, refer to ⇒ Electronic parts catalogue

13 - Pipe/hose assembly
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ To remove, first remove battery and battery tray ⇒ Electrical system; Rep. gr. 27
14 - Bracket
❑ Secured to bracket for ABS/EDL
15 - Bracket
❑ For ABS/EDL
16 - Seal or O-ring
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue
17 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
18 - Clutch slave cylinder
❑ Removing and installing
Protected by copyright. Copying for⇒ page
private 29
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
19 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 20 Nm
❑ 2x
20 - Bleeder valve
❑ 6 Nm
❑ Bleeding clutch system ⇒ page 39
21 - Dust cap
22 - Gearbox
23 - Bracket
24 - Bolt
❑ 20 Nm

38 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

6 Bleeding clutch system

Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-

Note

♦ The clutch system must be bled after performing work on the

hydraulic clutch mechanism.
♦ In the following steps make sure that no brake fluid escapes
onto the longitudinal member or onto the gearbox below.
♦ Prefilling the system is not necessary.
♦ Before bleeding clutch system, top up brake fluid reservoir to
„Max“ marking with brake fluid.
♦ Brake fluid specification ⇒ Rep. gr. 47 .

– Pull clutch pedal back to its normal rest position.

– Remove air cleaner housing completely ⇒ Rep. gr. 23 .
– Connect brake filling and bleeding equipment -VAS 5234- or
-V.A.G 1869- .
– To bleed system, use bleed hose -V.A.G 1238 B/3- - 670 mm
long, if necessary.
– Then connect bleeder hose to collector bottle of brake bleed‐
ing unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6. Bleeding clutch system 39

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Connect bleed hose to bleeder connection -arrow-.

– Now switch on bleeding equipment.
♦ Operating pressure 2.0 bar
– Open bleeder valve.
– Bleed off about 100 cm3 of brake fluid.
– Close bleeder valve.
– Rapidly pump clutch pedal through full range of travel 10 to 15
times.
– Open bleeder valve once again.
– Bleed off an additional 50 cm3 of brake fluid.
– Tighten bleeder valve to 6 Nm, detach bleeder hose and fit
protective cap.
– Detach brake filling and bleeding equipment -VAS 5234- from
brake fluid reservoir.
– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
– Install complete air Protected
cleanerby housing ⇒ Rep.
copyright. Copying gr. or23
for private .
commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

40 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

7 Exploded view - clutch release mechanism

1 - Gearbox
2 - Ball-head pin
❑ 25 Nm
❑ Remove existing grease
from contact surface of
release lever
❑ Lubricate with grease
for clutch plate splines -
G 000 100-
3 - Input shaft oil seal
❑ Pressed into guide
sleeve
❑ Removing ⇒ page 42
❑ Installing ⇒ page 43
4 - Guide sleeve
❑ With vulcanised O-ring
and oil seal for input
shaft
⇒ Item 3 (page 41)
❑ Renew guide sleeve if
O-ring is damaged
❑ Lubricate guide sleeve
in area of release bear‐
ing with grease for
clutch plate splines -
G 000 100-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Retaining
permitted spring
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Secure to clutch release
with respect to the correctness of information in this document. Copyright by AUDI AG.

lever
6 - Socket head bolt
❑ 20 Nm
7 - Clutch release lever
❑ Removing and installing together with release bearing ⇒ page 42
❑ Remove existing grease
❑ Lubricate surface which contacts ball-head pin with grease for clutch plate splines -G 000 100-
8 - Release bearing
❑ Do not wash out bearing; wipe clean only
❑ Renew bearing if noisy
❑ Detaching/attaching on release lever ⇒ page 42
❑ Lubricate surface which contacts release lever with grease for clutch plate splines -G 000 100-
9 - Bolt
❑ Tightening torque ⇒ Item 15 (page 28)
❑ 2x
10 - Clutch slave cylinder
❑ Removing ⇒ page 29
❑ Installing ⇒ page 32
11 - Plunger
❑ Lubricate end of plunger with grease for clutch plate splines -G 000 100-

7. Exploded view - clutch release mechanism 41

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

12 - Assembly bolt
❑ Secures the clutch release lever while installing gearbox
❑ Unscrew after gearbox has been installed

Note

If the assembly bolt

( ⇒ Item 12 (page 42) ) is not avail‐
able, an M8 x 35 bolt can be used
instead.

Removing and installing clutch release lever together with release

bearing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unhook spring -arrow 1-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Pull off clutch release lever -arrow 2- and clutch release bear‐
ing.
Perform installation in reverse sequence of removal.

Removing and installing clutch release bearing

– Press locking lugs -arrows- together on reverse side of clutch
release lever and remove release bearing -A- from clutch re‐
lease lever.
– To install, press release bearing -A- into clutch release lever
until locking lugs -arrows- engage.

Driving oil seal out of guide sleeve

42 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Driving oil seal into guide sleeve (drive in onto stop)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Exploded view - clutch release mechanism 43

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

8 Overview - servicing clutch

♦ ⇒ „8.1 Clutch identification“, page 44
♦ ⇒ „8.2 Exploded view - Sachs version clutch“, page 45
♦ ⇒ „8.3 Removing and installing clutch (Sachs version)“,
page 47
♦ ⇒ „8.4 Exploded view - LuK version clutch“, page 50
♦ ⇒ „8.5 Removing and installing clutch (LuK version)“,
page 52
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8.1 Clutch identification
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The clutch fitted in the vehicle is supplied by either „Sachs“ or

„LuK“.

With gearbox installed, the clutch version fitted can be distin‐

guished as follows:
– Remove centre noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .

A number of recesses -arrows- are located in lower area of sump

between engine -A- and gearbox -B-.
– Check the contour of the flywheel visible through the recesses.

44 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– The contour of the flywheel can also be checked by removing

the small cover plate -A-.

Round contour -arrows- = Sachs version clutch = -A-

– Servicing Sachs version clutch ⇒ page 45
Square contour -arrows 1- and additional annular groove
-arrow 2- = LuK version clutch = -B-.
or

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Round contour -arrows 1- and annular groove -arrow 2- = LuK

version clutch = -B-
– Servicing LuK version clutch ⇒ page 50

8.2 Exploded view - Sachs version clutch

Note

The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another
manufacturer must not be installed on the same vehicle.

8. Overview - servicing clutch 45

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Dual-mass flywheel
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Observe instructions for
removal ⇒ page 47
2 - Clutch plate
❑ Removing and installing
⇒ page 47
❑ Always renew pressure
plate as well
❑ Installation position
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ pagepermitted
49 unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
3 - Pressure plate
❑ With adjustment mech‐
anism
❑ Identification
⇒ page 47
❑ Removing and installing
⇒ page 47
❑ Checking ends of dia‐
phragm spring
⇒ page 49
❑ Checking spring con‐
nections and rivets
⇒ page 49
❑ Always renew clutch plate as well
❑ For correct version, refer to ⇒ Electronic parts catalogue
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ 6x
❑ Loosen and tighten gradually in small steps ⇒ page 47

46 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Identification of self-adjusting Sachs version clutch

♦ Pressure plate with stop mechanism (position sensor)
-arrow-.

Instructions for removing dual-mass flywheel

Note

Do not use an impact wrench or pneumatic wrench to remove

bolts -B-: this would severely damage the dual-mass flywheel.
The bolts must always be removed by hand.

– Rotate dual-mass flywheel -A- so that the bolts are aligned

centrally behind the holes -arrows-.
– When unscrewing bolts -B-, make sure the bolt heads do not
contact the flywheel -arrows- because this would damage the
flywheel when the bolts are turned further.

8.3 Removing and installing clutch (Sachs

version)
Special tools and workshop equipment required
♦ Counterhold tool -3067-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Overview - servicing clutch 47

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Centring mandrel -3190 A-

♦ Grease for clutch plate splines -G 000 100-

Removing
• Gearbox removed
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Apply counter-hold tool -3067- in order to loosen bolts.
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
• Stop -2- with pin -1- should come loose when the bolts are
slackened.
– If the stop does not come loose, push the pin towards the dual-
mass flywheel.
– Take off pressure plate and clutch plate.
Installing clutch (Sachs version)
Installation is carried out in reverse sequence; note the following:
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

♦ If required, always renew clutch plate and pressure plate to‐

gether.
♦ Select the correct clutch plate and pressure plate according to
engine code ⇒ Electronic parts catalogue .
♦ Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).

48 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installation position of clutch plate

• Marking „Getriebeseite“ (gearbox side) faces towards gearbox

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Checking spring connections and rivets

– Check spring connections between pressure plate and cover
for cracks and make sure rivets are seated tightly.
• Renew pressure plate if spring connections are broken or bad‐
ly bent, or if riveted fastenings are loose -arrows-.

Note

♦ If the clutch has burnt out, thoroughly clean the clutch housing,
flywheel and parts of the engine facing the gearbox in order to
reduce the smell of burnt linings.
♦ Clean input shaft splines and (in the case of a used clutch
plate) the hub splines. Remove corrosion and apply only a very
thin coating of grease for clutch plate splines -G 000 100- to
the splines. Then move clutch plate backwards and forwards
on input shaft until hub moves freely on shaft. It is important
to remove excess grease.
♦ Pressure plates have an anti-corrosion coating and are
greased. Only the contact surface may be cleaned, otherwise
the service life of the clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert bolts.

8. Overview - servicing clutch 49

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Reverse position of counter-hold tool -3067- when installing.

– Fit pressure plate onto centring pins.
– Use centring mandrel -3190 A- to centralise clutch plate.

To prevent the pressure plate from becoming distorted during in‐

stallation (causes clutch grab when driving off), always adhere to
the following procedure when installing the pressure plate:
– Make sure that the stop pin (position sensor) -arrow- is free to
move.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Working clockwise, tighten all six bolts consecutively in steps
of 90° (1/4 turn) until the housing makes contact with the fly‐
wheel.
• The stop pin -arrow- should then lift away from the pressure
plate.
– Working clockwise, tighten all 6 bolts to final torque consecu‐
tively. Tightening torque ⇒ Item 4 (page 46)

8.4 Exploded view - LuK version clutch

„SAC“ stands for „Self-Adjusting Clutch“.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

50 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Dual-mass flywheel
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of scoring, oil and
grease
❑ Observe instructions for
removal ⇒ page 52
2 - Clutch plate
❑ Removing and installing
⇒ page 52
❑ Always renew SAC
pressure plate as well
❑ The marking
„Getriebeseite“ (gear‐
box side), if provided,
faces towards pressure
plate/gearbox
❑ For correct version, re‐
fer to ⇒ Electronic
Protected by copyright. parts
Copying for private or commercial purposes, in part or in whole, is not
catalogue
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - SAC pressure plate
❑ Removing and installing
⇒ page 52
❑ Only fits on flywheel in
one position
❑ Checking ends of dia‐
phragm spring
⇒ page 53
❑ Check rivets and spring
connection ⇒ page 54
❑ Always renew clutch plate as well
❑ For correct version, refer to ⇒ Electronic parts catalogue
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ 6x
❑ Loosen and tighten gradually in small steps ⇒ page 52

8. Overview - servicing clutch 51

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing dual-mass flywheel

Note

Do not use an impact wrench or pneumatic wrench to remove

bolts -B-: this would severely damage the dual-mass flywheel.
Bolts -B- must always be removed by hand.

– Rotate flywheel -A- so that bolts -B- are aligned centrally be‐
hind the holes -arrows-.
– When unscrewing bolts -B-, make sure the bolt heads do not
contact the flywheel -arrows- because this would damage the
flywheel when the bolts are turned further.
Removing and installing dual-mass flywheel ⇒ Engine, mechan‐
ics; Rep. gr. 13

8.5 Removing and installing clutch (LuK ver‐

sion)
Special tools and workshop equipment required
♦ Counterhold tool -3067-

♦ Centring mandrel -3190 A-

♦ Grease for clutch plate splines -G 000 100-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

• Gearbox removed

52 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Attach counterhold tool -3067- before loosening bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
– Take off pressure plate and clutch plate.
Installing clutch (LuK version)
Installation is carried out in reverse sequence; note the following:

Note

♦ If required, pressure plate and clutch plate must always be

renewed together.
Protected by copyright. Select
Copying the orcorrect
for private pressure
commercial plate
purposes, in part orand clutch
in whole, is not
plate according
permitted to engine
unless authorised code
by AUDI AG. AUDI⇒AGElectronic parts
does not guarantee catalogue
or accept .
any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).

Checking position of adjustment mechanism (new pressure

plates only)
• The two edges -A- of the adjuster ring should be located be‐
tween the two notches -arrows B-.
• If the adjuster ring is in a different position on a new pressure
plate, the pressure plate and clutch plate must not be installed.
• The position of the adjuster ring can be outside the notches
on used clutches.

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.

8. Overview - servicing clutch 53

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Checking spring connections and rivets

– Check spring connections -arrows A- for damage and make
sure riveted joints -arrows B- are seated tightly.
• Renew pressure plate if spring connections are broken or bad‐
ly bent, or if riveted joints are loose.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation position of clutch plate permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Marking „Getriebeseite“ (gearbox side) faces towards gearbox

Note

♦ If the clutch has burnt out, thoroughly clean the clutch housing,
flywheel and parts of the engine facing the gearbox in order to
reduce the smell of burnt linings.
♦ Select the correct clutch plate and pressure plate according to
engine code ⇒ Electronic parts catalogue .
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.
♦ Pressure plates have an anti-corrosion coating and are
greased. Only the contact surface may be cleaned, otherwise
the service life of the clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert bolts.

– Reverse position of counter-hold tool -3067- when installing.

– Position pressure plate on centring pins.
– Use centring mandrel -3190 A- to centralise clutch plate.
To prevent the pressure plate from becoming distorted during in‐
stallation (causes clutch grab when driving off), always adhere to
the following procedure when installing the pressure plate:
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Working clockwise, tighten all six bolts consecutively in steps
of 90° (1/4 turn) until the housing makes contact with the fly‐
wheel.
– Working clockwise, tighten all 6 bolts to final torque consecu‐
tively. Tightening torque ⇒ Item 4 (page 51)

54 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

34 – Controls, housing
1 Overview - selector mechanism
♦ ⇒ „1.1 Exploded view - gear knob and gear lever boot“,
page 57
♦ ⇒ „1.2 Removing and installing gear knob with gear lever
boot“, page 57
♦ ⇒ „1.3 Separating gear lever boot from gear knob“,
page 58
♦ ⇒ „1.4 Exploded view - gear lever and selector housing on ve‐
hicles up to model year 2007“, page 59
♦ ⇒ „1.5 Exploded view - selector mechanism on vehicles from
model year 2008 onwards“, page 62
♦ ⇒ „1.6 Dismantling and assembling selector mechanism on
vehicles from model year 2008 onwards“, page 63
♦ ⇒ „1.7 Removing and installing selector mechanism“,
page 67
♦ ⇒ „1.8 Exploded view - gear selector cable and gate selector
cable up to model year 2007“, page 72
♦ ⇒ „1.9 Exploded view - gear selector cable and gate selector
cable from model year 2008 onwards“, page 75
♦ ⇒ „1.10 Removing and installing gear selector cable and gate
selector cable“, page 81
♦ ⇒ „1.11 Adjusting selector mechanism“, page 82
-Arrow A- gear selection movement
-Arrow B- gate selection movement

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Overview - selector mechanism 55

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

A - Gear selector cable (gear

selection movement)
B - Gate selector cable (gate
selection movement)
C - Heat shield
❑ Detach before removing
selector mechanism
1 - Gearbox selector lever
2 - Relay lever

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

56 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1.1 Exploded view - gear knob and gear lever boot

1 - Gear lever
2 - Noise insulation cover (low‐
er)
3 - Noise insulation cover (up‐
per)
4 - Gear knob
❑ Remove and install to‐
gether with gear lever
boot ⇒ page 57
5 - Gear lever boot
❑ Remove and install to‐
gether with gear knob
⇒ page 57
6 - Cover for centre console
❑ Remove and install to‐
gether with gear knob
and gear lever boot
⇒ page 57
7 - Connecting piece
❑ Connects gear lever
boot and gear knob
❑ Different versions ⇒
Electronic parts cata‐
logue
8 - Clamp
❑ Secures gear knob to
gear lever
❑ Secure with hose clip
pliers -V.A.G 1275-

1.2 Removing and installing gear knob with

gear lever boot
Special tools and workshop equipment
Protected by copyright. required
Copying for private or commercial purposes, in part or in whole, is not

♦ Hose clip pliers -V.A.G 1275-

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Overview - selector mechanism 57

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing

Note

The gear knob is removed together with the gear lever boot and
the cover for the centre console.

– Open ashtray (if fitted).

– Carefully pry gear lever boot off centre console -arrows-.
– Pull boot up and over gear knob.

– Open clip -arrow- and pull off gear knob together with boot.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
Installation is carried out in reverse sequence; note the following:
– Push gear knob together with boot onto gear lever as far as
stop.
– Secure gear knob to gear lever with clip -arrow-, using hose
clip pliers -V.A.G 1275- .

1.3 Separating gear lever boot from gear

knob
– Remove gear knob together with gear lever boot ⇒ page 57 .

58 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Unclip frame of gear lever boot from centre console cover

-arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Cut through the connecting piece with a sharp knife

with respect atcorrectness
to the the point
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
of information in this document. Copyright by AUDI AG.
marked -arrow-. Take care not to damage gear lever boot.
Installing
Installation is carried out in reverse sequence; note the following:
– Fit gear lever boot on gear knob, using a new connecting piece
-arrow-.
– Install gear knob together with boot ⇒ page 57 .

1.4 Exploded view - gear lever and selector housing on vehicles up to model
year 2007

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1. Overview - selector mechanism 59

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Floor plate
❑ Bend tabs open to re‐
move
❑ Renew
2 - Gasket
❑ Renew if damaged
3 - Gear lever
4 - O-ring
❑ Renew if damaged
5 - Retaining clip
❑ Renew
6 - Gate selector cable
❑ Removing and installing
⇒ page 81
❑ Adjusting ⇒ page 82
7 - Gear selector cable
❑ Removing and installing
⇒ page 81
❑ Adjusting ⇒ page 82
8 - Securing clip
❑ Renew
9 - Guide
❑ For spring
⇒ Item 26 (page 61)
10 - Bearing shell with damper
11 - Cover
12 - Bush
13 - Securing clip
❑ Removing and installing ⇒ page 61
14 - Spring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Bush permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
16 - Bolt
❑ 6 Nm
17 - Securing clip
18 - Bearing bush
19 - Gear lever guide
20 - Nut
❑ 10 Nm
21 - Gasket
❑ Between selector housing and floor
❑ Self-adhesive
22 - Selector housing
23 - Bearing bush
24 - Pivot pin
25 - Guide bush
❑ Press onto selector housing

60 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

26 - Spring
❑ Installing ⇒ page 61
27 - Bolt
❑ 5 Nm
28 - Gate selector lever

Removing and installing securing clip

– Hold gear lever -2- in position.
– Press spacer bush -3- in direction indicated -arrow-.
– Take off securing clip -1-.

Installing spring
– Insert arm -A- of spring in guide -1- from above.
– Pull down arm -B- of spring and insert it in the guide from be‐
low.

Note

The gate selector lever is removed to give a better illustration.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Overview - selector mechanism 61

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1.5 Exploded view - selector mechanism on vehicles from model year 2008
onwards

Note

Lubricate bearings and moving surfaces with grease -G 000 450 02- .

1 - Floor plate
❑ Bend tabs open to re‐
move
❑ Always renew
2 - Gasket
❑ Always renew
3 - Gear lever
❑ Can be removed and in‐
stalled without removing
gear lever guide
⇒ Item 15 (page 63)
4 - Damping washer
❑ Push onto gear lever as
far as stop -arrow-
5 - Retaining clip
❑ Take care not to dam‐
age selector cables
when removing.
❑ Renew
6 - Gate selector cable
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Installation position
⇒ page 55
7 - Bush
8 - Gear selector cable
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector mechanism
❑ Installation position ⇒ page 55
9 - Damper
10 - Bearing shell
❑ Will be damaged during removal
❑ Always renew
11 - Bush Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

12 - Securing clip with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing and installing ⇒ page 61

62 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

13 - Spring
14 - Bush
15 - Gear lever guide
16 - Nut
• M6 - 8 Nm
• M8 - 25 Nm
❑ 4x
17 - Gasket
❑ Between selector housing and floor
❑ Self-adhesive
❑ Glue onto selector housing
18 - Selector housing
❑ With spring and gate selector lever
❑ Spring and gate selector lever cannot be detached

1.6 Dismantling and assembling selector

mechanism on vehicles from model year
2008 onwards
Special tools and workshop equipment required
♦ Thrust block -T10083-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Dismantling
– Remove selector mechanism ⇒ page 67
– Using a screwdriver, bend open tabs -arrows- on all sides of
floor plate and remove floor plate.
– Remove gasket from selector housing.
– Remove gear selector cable and gate selector cable from se‐
lector housing ⇒ page 62 .

1. Overview - selector mechanism 63

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Lift top spring arm -A- over tab on gate selector lever.
– Using a screwdriver, press lugs -arrows- on ball socket to‐
wards ball on gear lever guide; if necessary, break off lugs.

– Prise ball socket -A- out of selector housing together with gear
lever guide and gear lever -B-.
– Then press ball socket -A- off ball on gear lever guide and
remove.

Note

♦ Note guides -A- when performing the following steps.

♦ They must not break off.

– Swivel bottom spring arm -arrow 1- onto stop on shoulder of

gate selector lever.

Caution

During the following

Protected steps,
by copyright. Copyingthe bottom
for private spring purposes,
or commercial arm (-arrow
in part or 1-)
in whole, is not
can become
permitteddislodged and
unless authorised bysnap
AUDI AG.downwards
AUDI AG does off the shoulder
not guarantee or accept any liability

of the gatewithselector lever.

respect to the correctness of information in this document. Copyright by AUDI AG.

– Pull gear lever guide upwards as far as stop and at the same
time pull ball-head pin -arrow 2- out of gate selector lever.
– Press spring -arrow 1- carefully off the shoulder of the gate
selector lever.
The spring arms will then compress „diagonally“.

64 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Then turn gear lever guide in direction of -arrow 1-.

• The pin -arrow 2- must be in the recess in the selector housing.
– Next, swivel gear lever guide out in direction of -arrow 3- to‐
gether with gear lever.

Assembling selector mechanism

– Release spring arms -A- and -B-.
• Spring arms -A- and -B- must point in opposite directions.
(Shown here with gear lever guide installed.)

– Insert gear lever guide into selector housing together with gear
lever.
• Pin -arrow 1- should be positioned just inside recess on se‐
lector housing.
– Turn gear lever guide in direction of -arrow 2- until ball-head
pin -A- is above recess on selector housing.

– Position selector housing with gear lever guide onto thrust

block -T10083- .
• The gear lever guide rests in the larger recess -arrow- in the
thrust block -T10083- .
• The gear lever guide should protrude out of the selector hous‐
ing as far as the stop.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Overview - selector mechanism 65

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Insert arm -A- of spring in guide from above.

– Pull arm -B- of spring downwards and insert it next to the guide
(towards ball head).

Note

For illustration purposes, only part of the gate selector lever is

shown.

– Carefully take selector housing off thrust block -T10083- to‐

gether with gear lever guide.

– Move gate selector lever rearwards as far as stop in direction

of -arrow 1-.
– Grease ball-head pin.
– Press ball-head pin into hole in gate selector lever -arrow 2-.
• Guides -A- and tabs -B- must not be damaged.

– Now insert
unlessgear lever guide (which is now fitted or
inaccept
selector
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised by AUDI AG. AUDI AG does not guarantee any liability
housing) into
with respect to thelarger recess
correctness -arrow-
of information indocument.
in this thrust Copyright
block -T10083-
by AUDI AG.
again.
• The gear lever guide should now protrude out of the selector
housing as far as the stop.

– Lift top spring arm -A- over pin on gate selector lever.
• Use a new ball socket -B-.
– Grease ball socket and ball of gear lever guide.
– Press ball socket onto ball of gear lever guide as far as stop.
– Remove selector housing from thrust block -T10083- .
– Press ball socket into selector housing in direction of
-arrows-.

66 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

• All four lugs -arrows- must engage.

– Lift top spring arm -A- over pin on gate selector lever into
guide.
– Insert bottom spring arm into guide.
– Fit gear lever, gear selector cable, gate selector cable and
floor plate ⇒ page 62 .
– Install selector mechanism ⇒ page 70 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.7 Removing and installing selector mech‐

anism
Removing
– Remove gear knob together with gear lever boot ⇒ page 57 .
– Remove ashtray or storage compartment in front section of
centre console ⇒ General body repairs, interior; Rep. gr. 68 .
– Lift out noise insulation covers above selector mechanism.
– Remove nuts -arrows-.
– Remove air cleaner housing completely ⇒ Rep. gr. 23 .

WARNING

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

1. Overview - selector mechanism 67

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove battery and battery tray -arrows- ⇒ Electrical system;

Rep. gr. 27 .

– Detach securing clip -arrow 1- for gear selector cable from

gearbox selector lever -A-.
Vehicles with metal relay lever -B-:
– Detach securing clip -arrow 2- for gate selector cable from re‐
lay lever -B-.
– Pull gate selector cable and gear selector cable off joint pins.

Plastic relay lever:

• To avoid damage to the gate selector cable, the cable end-
piece must be separated from the gate selector cable before
removal.
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn in direction of -arrow 2- to lock.
– Then press relay lever forwards (in direction of -arrow 3-).
• Detach cable end-piece only when relay lever is removed
⇒ page 80 .

– If necessary, move pipe/hose assembly -2- clear at bracket

-1-.
– Unscrew bolt -3- and detach bracket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

68 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Continued for all vehicles:

– Detach cable support bracket from gearbox -arrows-.

– Remove front cross member on underbody -arrows-.

Note

To prevent damage, the flexible couplings in the front exhaust

pipe must not be bent further than 10°.

– Disconnect exhaust system at clamp -1-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unbolt support bracket for exhaust system -arrows-.

– Tie up front exhaust pipe on underbody.

A3 Cabriolet:
– Remove bolts -1- and -2- and detach strut (left-side).

1. Overview - selector mechanism 69

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Continued for all vehicles:

– Remove rear cross member on underbody -nuts 1 and 2-.

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Detach exhaust system at rubber mountings -arrows-.

– Detach rear silencer at rubber mountings and remove rear
section of exhaust system.

– Remove nuts -arrows-.

– Remove lock washers -2- and -3-.
– Lower cover for vehicle underbody (on inside) until heat shield
-1- for centre tunnel can be removed.
– Swing selector housing down and remove with selector ca‐
bles.

Installing
Installation is carried out in reverse sequence; note the following:
– Install selector mechanism and tighten nuts -arrows-. Tight‐
ening torque ⇒ Item 20 (page 60) or ⇒ Item 16 (page 63) .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

70 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Route cables -1- from selector mechanism -2- to gearbox as

follows:
♦ After the point where they cross over -arrow-, the cables must
run parallel as far as the cable support bracket on the gearbox.
♦ Check that cable tie -arrow- securing selector cables is prop‐
erly fitted. Installation position ⇒ page 75 or ⇒ page 81
♦ The cables must be routed in the slot provided in heat shield
-3-.

Note

The enlargement shows the heat shield from above.

The holes in the cable end-pieces have different diameters.

Identification of cable end-pieces ⇒ page 73 or ⇒ page 77

– Apply a small quantity of grease -G 000 450 02- to pin

-arrow- of gearbox selector lever -1-.
– Push gear selector cable onto pin -arrow- and secure with se‐
curing clip -3-.
Metal relay lever -2-:
– Apply a small quantity of grease -G 000 450 02- to pin
-arrow- of relay lever -2-.
– Push gate selector cable onto pin -arrow- and secure with se‐
curing clip -4-.
Plastic relay lever -2-:
– Insert gate selector cable in cable end-piece.

Continued for all vehicles:

– Attach cable support bracket to gearbox -arrows-. Tightening
torque ⇒ Item 6 (page 72) or ⇒ Item 15 (page 77) .
– Adjust selector mechanism ⇒ page 82 .
– Install noise insulation covers above selector mechanism.
– Install ashtray in front section of centre console ⇒ General
body repairs, interior; Rep. gr. 68 .
– Install gear knob together with boot ⇒ page 57 .
– Install exhaust system and ensure stress-free alignment ⇒
Engine, mechanics; Rep. gr. 26 .
– Secure both tunnel cross-pieces on vehicle underside ⇒ En‐
gine, mechanics; Rep. gr. 26 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install battery tray and battery ⇒ Electrical system; Rep.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

1. Overview - selector mechanism 71

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1.8 Exploded view - gear selector cable and gate selector cable up to model
year 2007

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1 - Gear selector cable

❑ Removing and installing
⇒ page 81
❑ Adjusting ⇒ page 82
❑ Secure to gate selector
cable with cable tie
⇒ page 75
2 - Gate selector cable
❑ Removing and installing
⇒ page 81
❑ Adjusting ⇒ page 82
❑ Secure to gear selector
cable with cable tie
⇒ page 75
3 - Securing clips
4 - Selector housing
5 - Retaining clips
❑ Renew
6 - Bolt
❑ 20 Nm
7 - Cable support bracket
❑ Made of metal or plastic,
depending on version
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
8 - Grommet
❑ Mounting for cable sup‐
port bracket on gearbox
9 - Bush
10 - Cable end-piece
❑ Secures gate selector cable to relay lever
❑ Allocation ⇒ page 73
❑ Detaching from gate selector cable ⇒ page 75
11 - Cable end-piece Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Secures gear selector cable to gearbox selector lever

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Allocation ⇒ page 73
❑ Detaching from gear selector cable ⇒ page 75
12 - Securing clips
❑ Removing ⇒ page 75
❑ Renew

72 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

13 - Securing clip
❑ Removing ⇒ page 74
❑ Renew
14 - Bearing bushes
15 - Relay lever
❑ Installation position ⇒ page 74
16 - Slide block
17 - Gearbox selector lever
❑ With damper weight
❑ Installation position ⇒ page 74
❑ After installing, adjust selector mechanism ⇒ page 82
18 - Nut
❑ 23 Nm
❑ Self-locking
❑ Renew

Identification of cable end-pieces

The holes in the cable end-pieces
Protected byhave different
copyright. diameters.
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Cable end-piece for: with respect to the correctness Dimension
of information in „a“
this document. Copyright by AUDI AG.

Gear selector cable to gearbox selector lever 10 mm

Gate selector cable to relay lever 8 mm

Cable end-piece for: Dimension „a“

Gear selector cable to gearbox selector lever 20 mm
Gate selector cable to relay lever 18.5 mm

1. Overview - selector mechanism 73

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing gearbox selector lever

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.

Detaching securing clip from relay lever

– Pull up clip -arrow- and detach securing clip.

Installation position: gearbox selector lever/relay lever

1 - Gearbox selector lever
- With damper weight
2 - Relay lever
- Locates in guide rail of gearbox selector lever via slide block
-arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

74 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Detaching cable end-pieces from gear selector cable and gate

selector cable
– Pull locking mechanism forwards -arrow 1- onto stop and then
turn in direction of -arrow 2- to lock.
– Take cable -B- out of cable end-piece -A-.

Detaching and securing gear selector cable and gate selector ca‐
ble
Detaching
– Lift up tab and detach securing clip -3- for gear selector cable
from gearbox selector lever -1-. Then pull gear selector cable
off pin -arrow-.
– Lift up tab and detach securing clip -4- for gate selector cable
from relay lever -2-. Then pull gate selector cable off pin
-arrow-.
Securing

Note

♦ Renew securing clips.

♦ Apply a small quantity of grease -G 000 450 02- to the pins
-arrows-.

– Push gear selector cable onto gearbox selector lever -1- and
secure with securing clip -3-.
– Push gate selector cable onto relay lever -2- and secure with
securing clip -4-.

Position of cable tie securing selector

Protected cables
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Wrap cable tie round selector cables
with respect incorrectness
to the a „figure-of-eight“
of information in this document. Copyright by AUDI AG.
-arrow- and secure cable tie as shown in illustration.

1.9 Exploded view - gear selector cable and gate selector cable from model
year 2008 onwards

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1. Overview - selector mechanism 75

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Selector mechanism cover

2 - Slide block
3 - Relay lever
❑ Made of plastic
❑ Different versions avail‐
able; for correct version
refer to ⇒ Electronic
parts catalogue
❑ Installation position
⇒ page 78
❑ Detaching and securing
relay lever (with detentProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
catch) at selector mech‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

anism cover
with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 79
❑ Detaching and securing
relay lever (with clip) at
selector mechanism
cover ⇒ page 80
4 - Cable end-piece
❑ Secures gate selector
cable to relay lever
❑ Allocation ⇒ page 77
❑ Detaching from gate se‐
lector cable
⇒ page 78
5 - Gearbox selector lever
❑ With damper weight
❑ Fitting ⇒ page 78
❑ Installation position
⇒ page 78
❑ After installing, adjust
selector mechanism
⇒ page 82
6 - Nut
❑ Self-locking
❑ Renew
❑ 23 Nm
7 - Cable end-piece
❑ Secures gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 77
❑ Detaching from gear selector cable ⇒ page 78
8 - Securing clip
❑ Removing ⇒ page 79
❑ Renew
9 - Retaining clips
❑ Renew
10 - Gate selector cable
❑ Removing and installing ⇒ page 81
❑ Adjusting ⇒ page 82
❑ Secure to gear selector cable with cable tie ⇒ page 81

76 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

11 - Selector housing
12 - Retaining clips
❑ Renew
13 - Gear selector cable
❑ Detaching and securing at gearbox selector lever ⇒ page 79
❑ Removing and installing ⇒ page 81
❑ Adjusting ⇒ page 82
❑ Secure to gate selector cable with cable tie ⇒ page 81
14 - Cable support bracket
15 - Bolt
❑ 20 Nm
16 - Grommet
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

17 - Bush
with respect to the correctness of information in this document. Copyright by AUDI AG.

18 - Oil seal
❑ For selector shaft
❑ Renewing ⇒ page 174
19 - Clip
❑ For relay lever (only from 08.2008 onwards)

Identification of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for: Dimension „a“
-1- Gear selector cable to gearbox selector lever 8.5 mm
-2- Gate selector cable to relay lever 10 mm

1. Overview - selector mechanism 77

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing gearbox selector lever

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.

Installation position: gearbox selector lever/relay lever

1 - Gearbox selector lever
- With damper weight
2 - Relay lever
- Locates in guide rail of gearbox selector lever via slide block
-arrow-.

Detaching cable end-pieces from gear selector cable and gate

selector cable
– Pull locking mechanism forwards -arrow 1- onto stop and then
turn in direction of -arrow 2- to lock.
– Take cable -B- out of cable end-piece -A-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

78 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Detaching and securing gear selector cable at gearbox selector

lever
Detaching
– Lift up tab and detach securing clip -1- for gear selector cable
from gearbox selector lever -2-.
– Pull gear selector cable off pin -arrow-.
Securing

Note

♦ Renew securing clip for gear selector cable.

♦ Apply a small amount of grease -G 000 450 02- to pin
-arrow-.

– Push gear selector cable onto gearbox selector lever -2- and
secure with securing clip -1-.

Detaching and securing relay lever (with detent catch) at gearbox

selector lever (selector mechanism cover)
Detaching
– Press detent -arrow 1- down onto stop and remove relay lever
together with cable end-piece. Move relay lever in normal di‐
rection of operation.

Note

-Arrow 2- can be disregarded.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Securing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– Press cable end-piece onto relay lever ⇒ page 80 .

– Insert relay lever with cable end-piece as far as stop.
• Relay lever is secured by detent -arrow 1-.
• Cable end-piece is secured by detent -arrow 2-.
• Ensure that components engage securely.

1. Overview - selector mechanism 79

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Detaching and securing relay lever (with clip) at gearbox selector

lever (selector mechanism cover)
Detaching
– Remove clip -arrow 1- and take off relay lever together with
cable end-piece.
Securing

Note

Lubricate all bearings and moving surfaces with grease -G 000

450 02- .

– Insert relay lever with cable end-piece as far as stop.

– Press on clip -arrow 1-, making sure it engages securely.

Note

-Arrow 2- can be disregarded.

Levering cable end-piece for gate selector cable off relay lever
• Relay lever removed
– Apply plain slot screwdriver -A- between bush -B- and relay
lever.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing cable end-piece for gate selector cable onto relay lever
• Relay lever removed
• Press on cable end-piece only at bush -arrow-.
• Cable end-piece must move freely on relay lever.
• Cable end-piece must be behind detent.
– Ensure that components engage securely.

80 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Position of cable tie securing selector cables

– Wrap cable tie round selector cables in a „figure-of-eight“
-arrow- and secure cable tie as shown in illustration.

1.10 Removing and installing gear selector

cable and gate selector cable
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove selector mechanism ⇒ page 67
– Using a screwdriver, bend open tabs -arrows- for selector
mechanism on floor plate and remove floor plate.
– Remove gasket.

– Take off securing clips -1 ... 4- and detach gear selector cable
and gate selector cable from selector housing.

Note

♦ Securing clips -1 and 4- on the selector mechanism are dis‐

continued from model year 2008 onwards.
♦ Then press cables off gate selector lever and gear lever guide.

Release cable end-pieces -A- for gate selector cable and gear
selector cable -B- as follows:
– Push locking sleeve forwards as far as stop -arrow 1-.
– Turn locking sleeve as far as it will go in direction of arrow
-2- so that it engages.
– Detach cable end-pieces from cables.

1. Overview - selector mechanism 81

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Pull off securing clips -1- and -2-.

– Detach cable support bracket from cables.

Installing
Installation is carried out in reverse sequence; note the following:
– Secure gear selector cable and gate selector cable to selector
housing with securing clips -1 … 4-.

Note

♦ Securing clips -1 and 4- on the selector mechanism are dis‐

continued from model year 2008 onwards.
♦ Then press cables onto gate selector lever and gear lever
guide.

– Fit gasket and secure floor plate to selector mechanism by

bending over tabs -arrows-.
– Install selector mechanism ⇒ page 70 .
– Adjust selector mechanism ⇒ page 82 .

1.11 Adjusting selector mechanism

Special tools and workshop equipment required
♦ Locking pin -T10027A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Requirements for adjustment

• Gear selector linkage must be in proper condition and undam‐
aged.

82 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

• Selector mechanism must move freely.

• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
Adjusting
– Open ashtray.
– Carefully pry gear lever boot off centre console -arrows-.
– Pull boot up and over gear knob.
– With gearbox in neutral, guide gear lever to the left into 1st/
2nd gear gate.

– Pull noise insulation covers slightly to one side.

– Lock gear lever in position with locking pin -T10027A- .

Note

The noise insulation covers are removed to give a better illustra‐

tion.

– Remove air cleaner housing completely ⇒ Rep. gr. 23 .

ProtectedRelease
by copyright.cable
Copyingend-pieces for gate
for private or commercial selector
purposes, in part cable and
or in whole, gear
is not se‐
permittedlector cable as
unless authorised follows:
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Push locking sleeves on gear selector cable and gate selector
cable forward as far as they will go -arrow 1-.
– Turn locking sleeve as far as it will go in direction of arrow
-2- so that it engages.

Note

It should now be possible to move the cables in the cable end-

pieces.

• Gearbox in neutral.

1. Overview - selector mechanism 83

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Lock the selector shaft as follows:

– Push selector shaft down into 1st/2nd gear gate in direction of
-arrow 1-. At the same time, turn locking pin -A- in direction of
arrow -2- until it engages in selector shaft.
The selector shaft is then locked and can no longer be moved.
– Ensure that the gate selector cable and the gear selector cable
are located free of tension in the cable end-pieces.

– Now turn locking sleeves on gear selector cable and gate se‐
lector cable as far as they will go in the direction indicated
-arrow-.
The spring presses
Protected the locking
by copyright. Copying forsleeve
private or back intopurposes,
commercial the original
in part or po‐
in whole, is not
sition. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Cable adjustment is now complete.

– Now turn locking pin -A- back to original position (direction of

-arrow-).
– Pull locking pin -T10027A- out of selector mechanism.

84 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Check gear lever setting as follows:

• The gear lever should rest in the 3rd/4th gear gate when the
gearbox is in neutral.
– Depress clutch.
– Select all gears several times. Pay particular attention to the
operation of the reverse gear locking mechanism.
Should a gear fail to engage smoothly after repeated selection,
check the play (lift movement) of the selector shaft as follows:
– Engage 1st gear.
– Push gear lever as Protected
far as itbywill go to the left and release.
copyright. Copying for private or commercial purposes, in part or in whole, is not

– At the same time observe selector shaft onof gearbox

information in(2nd me‐ Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness this document.
chanic).
– The selector shaft should move up and down approx. 1 mm
(in direction of -arrow-) when the gear lever is moved.
If this is not the case, adjust selector mechanism again
⇒ page 82 .
– Fit gear lever boot.
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

1. Overview - selector mechanism 85

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

2 Removing and installing gearbox -

vehicles with 1.6 ltr. TDI engine
♦ ⇒ „2.1 Removing gearbox - vehicles with 1.6 ltr. TDI engine“,
page 86
♦ ⇒ „2.2 Installing gearbox - vehicles with 1.6 ltr. TDI engine“,
page 94

2.1 Removing gearbox - vehicles with 1.6 ltr. TDI engine

Special tools and workshop

equipment required
♦ Support bracket -10 - 222
A-
♦ Gearbox support -3282-
♦ Pin -3282/29-
♦ Adjustment plate -3282/39-
♦ Engine and gearbox jack -
V.A.G 1383 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

86 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Thrust piece -T10148-

♦ Spindle from assembly device -3066- or M8 x 105 bolt

♦ Grease for clutch plate splines -G 000 100-

Procedure

Note

Re-attach all cable ties at the same locations when re-installing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery ⇒ Electrical system; Rep. gr. 27 .

– Remove air cleaner housing completely ⇒ Rep. gr. 23 .

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 87
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove battery tray -arrows- (detach front of battery tray from
air duct if applicable).

– If fitted, cut open cable tie -arrow- for protective cover.

– Unplug electrical connector -2-.
– Push back protective cover and disconnect B+ wire from start‐
er solenoid.
– Disconnect earth wire -1-.
– Remove top starter mounting bolt.

– Pull locking mechanism forwards in direction of -arrow 1- onto

stop and then turn in direction of -arrow 2- to lock.
– Press relay lever Protected
forwards (in direction
by copyright. ofprivate
Copying for -arrow 3-) andpurposes,
or commercial pull in part or in whole, is not
out gate selector cable.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove clip -arrow 1- and take off relay lever together with
cable end-piece.
– Detach securing clip -arrow 2- and pull gear selector cable off
gearbox selector lever -A-.

88 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Detach cable support bracket from gearbox -arrows-.

Note

Items -A- and -B- can be disregarded.

– Tie cables with cable support bracket to one side.

– Move pipe -2- clear at bracket -1-.

– Unscrew bolt -3- and detach bracket.

– Detach gearbox support -1-.

– Remove clutch slave cylinder -arrows- and place to one side;
do not disconnect pipe.

Caution

Do not depress clutch pedal after removing clutch slave cylin‐

der.

– Remove engine/gearbox securing bolts -1- and -2- (accessible

from above).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 89
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Press release tabs and disconnect crankcase breather hose

-1-.
– Move vacuum hoses clear -arrows-.
– Remove bolt -2-, pivot air intake hose to the rear and detach
from turbocharger.

– Assemble support bracket -10 - 222 A- as shown in illustration

and set up on wing panel flanges.
– Engage lifting hooks of spindles on engine lifting eyes (left and
right).
– Take up weight of engine/gearbox assembly with spindles; do
not lift.
– Raise vehicle.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove front left wheel.

– Remove noise insulation -1- ⇒ General body repairs, exterior;
Rep. gr. 50 .

– A3 Cabriolet: Remove noise insulation frame -arrow- ⇒ Gen‐

eral body repairs, exterior; Rep. gr. 50 .

90 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove front section of wheel housing liner on both sides ⇒

General body repairs, exterior; Rep. gr. 66 .

Vehicles with start/stop system

– Unplug electrical connector -2- from gearbox neutral position
sender -G701- .
Continued for all vehicles
– Unplug electrical connector -3- at reversing light switch -F4- .
– Remove nut -1- and detach bracket
Protected for wiring.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bottom starter mounting bolttoand
with respect take out
the correctness starter. in this document. Copyright by AUDI AG.
of information

– Release hose clips -1- and -2- and remove air hose.

– If fitted, detach heat shield for drive shaft (right-side)

-arrows-.
– Unbolt drive shafts (left and right) from flange shafts on gear‐
box.
– Lift drive shafts (left and right) up and secure with cable tie.

Note

Make sure you do not damage surface coating on drive shafts.

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 91
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove bolt -arrow- securing flange shaft (right-side). To do

so, screw two bolts into flange and counterhold flange shaft
with suitable lever.
– Detach flange shaft.

Note

Before removing flange shaft, check oil seal for damage. A leak‐
ing oil seal must be renewed when fitting flange shaft.

– Screw spindle -A- of assembly device -3066- into threaded

piece in differential. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert thrust piece -T10148- and secure with nut -B-.
with respect to the correctness of information in this document. Copyright by AUDI AG.

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 differen‐
tial.

– Remove bolts -1, 2, 3- and detach pendulum support.

– Remove bolts -arrows- on gearbox mounting.

92 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Lower engine/gearbox assembly using spindle of support

bracket -10 - 222 A- until distance -a- is obtained between
gearbox housing and gearbox mounting.
• Dimension -a- = 50 mm

– Unbolt gearbox bracket -A- from gearbox -arrows-.

To remove gearbox „0A4“ set up gearbox support -3282- with ad‐

justment plate -3282/39- .
– Insert gearbox support
Protected-3282- in engine
by copyright. Copying forand gearbox
private jack
or commercial -
purposes, in part or in whole, is not
V.A.G 1383 A- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw support elements -A- and pin -3282/29- (-C-) into ad‐
justment plate , as illustrated.
– Place engine and gearbox jack -V.A.G 1383 A- underneath
vehicle.
• The arrow symbol -B- on the adjustment plate points in the
direction of travel.

– Align adjustment plate -3282/39- parallel to gearbox and lock

safety support on gearbox.
– Screw pin -3282/29- into hole for bolt securing pendulum sup‐
port to gearbox.
– Support gearbox from underneath by raising engine and gear‐
box jack -V.A.G 1383 A- .

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 93
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove remaining engine/gearbox securing bolts -5- and

-6-.
– Press gearbox off dowel sleeves.
– Pull gearbox off engine.

– Carefully lower gearbox using engine and gearbox jack -V.A.G

1383 A- and ensure sufficient clearance between sleeve -1-
and pressure plate -arrow- to prevent damage.
– While lowering gearbox, change position of gearbox using
spindles on gearbox support -3282- .

– If necessary, re-install flange shaft (right-side) and tighten

countersunk bolt -arrow- to 25 Nm.
Transporting gearbox ⇒ page 121

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 Installing gearbox - vehicles with 1.6 ltr.

TDI engine
Installation is carried out in reverse sequence; note the following:
Please note the information in the table below - „Checking gear
oil and filling up with gear oil“
„Checking gear oil level and filling up with gear oil“
»No« »Yes« »Yes«
Gearbox Genuine X
part
No oil es‐ X
caping
Was com‐ X
pletely dis‐ Before in‐
mantled stalling
⇒ Item 3
(page 164)
Oil capacity
⇒ page 1

94 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

„Checking gear oil level and filling up with gear oil“

Was parti‐ X
ally dis‐ After instal‐
mantled ling
• (gear‐ ⇒
box page 132
housing
and
clutch
housing
were not
separa‐
ted)

Note

♦ The special tools required are listed in the procedure for

⇒ „2.1 Removing gearbox - vehicles with 1.6 ltr. TDI engine“,
page 86 .
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew oil seals and gaskets, and bolts which are tightened by
turning through a specified angle.
♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
♦ Re-attach all cable ties at the same locations when re-instal‐
ling.
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.

– Check that dowel sleeves -A- for centralising engine/gearbox

are in the cylinder block; install any missing dowel sleeves.
If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox noise
(gears will make rattling noises).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 95
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Make sure that the intermediate plate is engaged on the seal‐

ing flange and fitted on the dowel sleeves -arrows-.
– Check clutch release bearing for wear and renew if necessary.
– Lubricate surface which contacts ball-head pin with grease for
clutch plate splines -G 000 100- .

– Insert gearbox support -3282- in engine and gearbox jack -

V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate -3282/39- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw support elements -A- and pin -3282/29- (-C-)authorised
permitted unless into ad‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
justment plate , as illustrated. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Align adjustment plate -3282/39- parallel to gearbox and lock

safety support on gearbox.
– Screw pin -3282/29- into hole for bolt securing pendulum sup‐
port to gearbox.
– Place engine and gearbox jack -V.A.G 1383 A- underneath
vehicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.

– Remove flange shaft (right-side) -arrow- when installing a new

gearbox or exchange gearbox.
– Check flange shaft oil seals for leaks and renew if necessary
⇒ page 213 .

96 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Screw spindle -A- of assembly device -3066- into threaded

piece in differential.
– 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 differen‐
tial.

– Carefully lift gearbox using engine and gearbox jack -V.A.G

1383 A- and ensure sufficient clearance between sleeve -1-
and pressure plate -arrow- to prevent damage.
– Bring gearbox into position.
– Install bottom engine/gearbox securing bolts. Tightening tor‐
ques ⇒ page 100

– Re-install flange shaft (right-side) and tighten countersunk bolt

-arrow-. Tightening torque ⇒ Item 12 (page 230)
– Detach gearbox support -3282- with adjustment plate
-3282/39- from gearbox after
Protected bolting Copying
by copyright. gearbox andorengine
for private to‐
commercial purposes, in part or in whole, is not
gether. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit gearbox bracket -A- with new bolts -arrows- and tighten.
Tightening torque ⇒ Item 8 (page 122)
– Install top engine/gearbox securing bolts. Tightening torques
⇒ page 100
– Lift engine/gearbox assembly slightly via the spindles of sup‐
port bracket -10 - 222 A- .

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 97
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Align engine/gearbox in installation position. To do so, raise

engine/gearbox until gearbox bracket makes full contact with
gearbox mounting.

Caution

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 gear‐
box up with engine and gearbox jack .

– Bolt gearbox bracket onto left engine/gearbox mounting using

new bolts -arrows-. Tightening torque ⇒ Item 12 (page 123)

WARNING

Do not remove support bracket -10 - 222 A- until all bolts se‐
curing the left-hand engine/gearbox mounting have been tight‐
ened to the specified torque.

– Check adjustment of assembly mountings; adjust if necessary

⇒ Engine, mechanics; Rep. gr. 10 .

– Fit pendulum support with new bolts -1 … 3- in accordance

with installation instructions ⇒ page 127 . Tightening torques
⇒ page 122
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– If removed earlier, bolt on heat shield for drive shaft (right-
side).

– Install clutch slave cylinder -arrows-. Tightening torque

⇒ Item 15 (page 28)
– Install gearbox supportProtected
-1-. Tightening torque
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Item 1 (page 122) with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install starter ⇒ Electrical system; Rep. gr. 27 .

98 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Tighten nut -1- for bracket.

– Plug electrical connector -3- in at reversing light switch -F4- .
Vehicles with start/stop system
– Attach connector -2- to gearbox neutral position sender -
G701- .

Continued for all vehicles

– Secure cable support bracket -arrows-. Tightening torque
⇒ Item 15 (page 77)
– Install bracket -B- and attach clutch line -A-. Tightening torque
⇒ Item 20 (page 28)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit relay lever and secure with clip -arrow 1-.

– Attach gear selector cable to gearbox selector lever -A- and
secure with securing clip -arrow 2-.
– Insert gate selector cable in cable end-piece and adjust se‐
lector mechanism ⇒ page 82 .
– A3 Cabriolet: Install frame for noise insulation ⇒ General body
repairs, exterior; Rep. gr. 50 .
– Install front sections of wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 .
– Install noise insulation under engine/gearbox ⇒ General body
repairs, exterior; Rep. gr. 50 .
– Fit front left wheel ⇒ Rep. gr. 44 .

– Install battery tray -arrows- and battery ⇒ Electrical system;

Rep. gr. 27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .

2. Removing and installing gearbox - vehicles with 1.6 ltr. TDI engine 99
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Tightening torques
Engine/gearbox securing bolts
Item Bolt Qty. Nm
1 M 12 x 55 1 80
2 M 12 x 55 1 80
3 1)2) M 12 x 150 1 80
4 1)2) M 12 x 150 1 80
5 M 10 x 50 3 40
6 M 12 x 60 1 80
A Dowel sleeves for 2
centralising
• 1) Bolt with stud M8.
• 2) Also starter to gearbox

Component Nm
Bracket for electrical wiring at bottom starter bolt 23
Heat shield for drive shaft to cylinder block, M10 25 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

100 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3 Removing and installing gearbox -

vehicles with 1.9 ltr. TDI engine
♦ ⇒ „3.1 Removing gearbox - vehicles with 1.9 ltr. TDI engine“,
page 101
♦ ⇒ „3.2 Installing gearbox - vehicles with 1.9 ltr. TDI engine“,
page 111

3.1 Removing gearbox - vehicles with 1.9 ltr. TDI engine

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Special tools and workshop with respect to the correctness of information in this document. Copyright by AUDI AG.

equipment required
♦ Support bracket -10 - 222
A-
♦ Gearbox support -3282-
♦ Pin -3282/29-
♦ Adjustment plate -3282/39-
♦ Engine and gearbox jack -
V.A.G 1383 A-

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 101
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Thrust piece -T10148-

♦ Spindle from assembly device -3066- or M8 x 105 bolt

♦ Grease for clutch plate splines -G 000 100-

Note

All cable ties which are released or cut open during removal must
be fitted in the same position when installing.

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

– Press release tab -arrow- and remove cover -1- over battery.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

102 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– With ignition switched off, disconnect earth wire -arrow- at

battery.

– Remove engine cover panel ⇒ Engine, mechanics; Rep. gr.

10 .
– Disconnect vent hose -1- and air hoses -3- and -5-.
– Unplug electrical connector -2- at air mass meter -G70- .
– Remove bolt -4- and take out air cleaner housing.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove battery tray -arrows-.

– Detach front of battery tray from air duct.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 103
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Detach cable support bracket from gearbox -arrows-.

– Remove bracket -B- from gearbox and disconnect from pipe/
hose assembly -A-.

Metal relay lever -B-:

– Detach securing clip -arrow 1- from gearbox selector lever
-A- and pull off gear selector cable.
– Detach securing clip -arrow 2- from relay lever -B- and pull off
gate selector cable.
– Pull off securing clip -arrow 3- and remove relay lever -B-.

Plastic relay lever

– Detach securing clip -arrow 1- and pull gear selector cable off
gearbox selector lever -A-.
– Detach gate selector cable from cable end-piece ⇒ page 88 .
– Press detent -arrow 2- down onto stop and remove relay lever
together with cable end-piece. Move relay lever in normal di‐
rection of operation.

Note

From 08.2008 onwards the relay lever is secured with a clip

⇒ page 31 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Continued for all vehicles:

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tie cables with cable support bracket to one side.

104 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Unplug electrical connectors -1- at starter and -4- at reversing

light switch -F4- .
– Unscrew wire -2- at starter and earth wire -3-.
– Move wiring clear.
– Remove top starter mounting bolt.

– Remove gearbox support -arrows A-.

– Detach clutch slave cylinder -arrows B-, move to one side and
secure with wire. Do not disconnect pipes.

Caution

Do not depress clutch pedal after removing clutch slave cylin‐

der.

– Remove upper engine/gearbox securing bolts.

– Set up support bracket -10 - 222 A- with adapters -10 - 222 A /

3- on wing mounting flanges.
– Engage lifting hooks of spindles on engine lifting eyes.
– Take up weight of engine/gearbox assembly with spindles; do
not lift.
– Raise vehicle.
– Remove front left wheel.
– Turn steering to the left.

Audi A3
– Remove centre noise insulation (fasteners -1 ... 3-).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 105
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Audi A3 Cabriolet
– Remove noise insulation -1- ⇒ General body repairs, exterior;
Rep. gr. 50 .

– Remove noise insulation frame -arrow- ⇒ General body re‐

pairs, exterior; Rep. gr. 50 .

Continued for all vehicles

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove front section of wheel housing liner (left-side) ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 .

– Gearbox for vehicles with start/stop system: unplug connector

-arrow- from gearbox neutral position sender -G701- .

106 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove nut -arrow- and detach bracket for electrical wiring.

– Remove bottom starter mounting bolt and take out starter.

– If fitted, unbolt heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shafts (left and right) from gearbox flange shafts.
– Lift drive shafts as far as possible and tie in place. Do not
damage surface coating.

Note

The left drive shaft should be tied up as far forward as possible.

– Unplug connector -1-.

– Remove bolts -2- and -3- and detach strut -A-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unbolt support bracket for exhaust system -arrows-.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 107
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Disconnect exhaust system at clamp -arrows-.

Note

To prevent damage, the flexible couplings in the front exhaust

pipe must not be bent further than 10°.

– Tie up front exhaust pipe on underbody.

– Lift retaining clips -arrows- slightly and remove air intake hose
(left-side).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove bolts -1 ... 3- and detach pendulum support.

– Remove hexagon bolts -arrows- at left mounting from gearbox

mounting.

108 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Adjust spindles of support bracket -10 - 222 A- to lower gear‐

box by distance -a-.
• Dimension -a- = 50 mm

– Unbolt gearbox bracket -A- from gearbox -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove securing bolt -arrow- for flange shaft. To do this,

screw two bolts into flange and counterhold flange shaft with
suitable lever.

Note

Before removing flange shaft, check oil seal for damage. A leak‐
ing oil seal must be renewed when fitting flange shaft.

– Pull out flange shaft and spring.

– Screw spindle -A- of assembly device -3066- into threaded

piece in differential.
– 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 differen‐
tial.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 109
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove bolt -1-.

– Lift out cover plate -2-.

Note

Shown in illustration with gearbox removed.

To remove gearbox „0A4“ set up gearbox support -3282- with ad‐

justment plate -3282/39- .
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .

– Bolt on support elements -A- and -C-, as illustrated on adjust‐

ment plate .
– Place engine and gearbox jack -V.A.G 1383 A- under vehicle;
arrow symbol -B- on adjustment plate points to front of vehicle.

– Align adjustment plate parallel to gearbox and lock safety sup‐

port on gearbox.
– Remove bottom engine/gearbox connecting bolts.

– Carefully pull gearbox off dowel sleeves.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

110 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Tilt gearbox to the front by turning spindle of gearbox support

-3282- in direction of -arrow-.

– Push gearbox
permittedforwards slightly andAG.bring it does
intonotthe position
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AUDI AG guarantee or accept any liability
shown. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Lower gearbox out of vehicle. When removing gearbox, en‐
sure sufficient clearance between sleeve -1- and pressure
plate -arrow- to prevent damage.

– If necessary, re-install flange shaft (right-side) and tighten

countersunk bolt -arrow- to 25 Nm.
Transporting gearbox ⇒ page 121

3.2 Installing gearbox - vehicles with 1.9 ltr.

TDI engine
Installation is carried out in reverse sequence; note the following:
Please note the information in the table below - „Checking gear
oil and filling up with gear oil“
„Checking gear oil level and filling up with gear oil“
»No« »Yes« »Yes«
Gearbox Genuine X
part
No oil es‐ X
caping

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 111
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

„Checking gear oil level and filling up with gear oil“

Was com‐ X
pletely dis‐ Before in‐
mantled stalling
⇒ Item 3
(page 164)
Oil capacity
⇒ page 1
Was parti‐ X
ally dis‐ After instal‐
mantled ling
• (gear‐ ⇒
box page 132
housing
and
clutch
housing
were not
separa‐
ted)

Note

♦ The special tools required are listed in the procedure for

⇒ „3.1 Removing gearbox - vehicles with 1.9 ltr. TDI engine“,
page 101 .
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew oil seals and gaskets, and bolts which are tightened by
turning through a specified angle.
♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
♦ All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease for clutch plate splines -G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.

– Check that dowel sleeves -A- for centralising engine/gearbox

are in the cylinder block; install any missing dowel sleeves.
If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox noise
(gears will make rattling noises).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

112 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Make sure that the intermediate plate is engaged on the seal‐

ing flange and fitted on the dowel sleeves -arrows-.
– Check clutch release bearing for wear and renew if necessary.
– Lubricate surface which contacts ball-head pin with grease for
clutch plate splines -G 000 100- .

– Insert gearbox support -3282- in engine and gearbox jack -

V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate -3282/39- .
– Screw support elements -A- and pin -3282/29- (-C-) into ad‐
justment plate , as illustrated.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Align adjustment
with respect plateof-3282/39-
to the correctness parallel
information in this toCopyright
document. gearbox andAG.
by AUDI lock
safety support on gearbox.
– Screw pin -3282/29- into hole for bolt securing pendulum sup‐
port to gearbox.
– Place engine and gearbox jack -V.A.G 1383 A- underneath
vehicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.

– Tilt gearbox to the front by turning spindle of gearbox support

-3282- in direction of -arrow-.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 113
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove flange shaft (right-side) -arrow- when installing a new

gearbox or exchange gearbox.
– Check flange shaft oil seals for leaks and renew if necessary
⇒ page 213 .

– Screw spindle -A- of assembly device -3066- into threaded

piece in differential.
– 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 differen‐
tial.

– Carefully lift gearbox using engine and gearbox jack -V.A.G

1383 A- and ensure sufficient clearance between sleeve -1-
and pressure plate -arrow- to prevent damage.
– Bring gearbox into position.
– Install bottom engine/gearbox securing bolts. Tightening tor‐
ques ⇒ page 120
– Detach gearbox support -3282- with adjustment plate
-3282/39- from gearbox after bolting gearbox and engine to‐
gether.

– Insert cover plate -2- so that that bottom lug engages in cylin‐
der block and secure with bolt -1-.

Note

Shown in illustration with gearbox removed.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

114 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Re-install flange shaft (right-side) and tighten countersunk bolt

-arrow-. Tightening torque ⇒ Item 12 (page 230)

– Fit gearbox bracket -A- with new bolts -arrows- and tighten.
Tightening torque ⇒ Item 8 (page 122)
– Install top engine/gearbox securing bolts. Tightening torques
⇒ page 120
– Lift engine/gearbox assembly slightly via the spindles of sup‐
port bracket -10 - 222 A- .

– Align engine/gearbox in installation position. To do so, raise

engine/gearbox until gearbox bracket makes full contact with
gearbox mounting.

Caution

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 gear‐
box up with engine and gearbox jack .

– Bolt gearbox bracket onto left engine/gearbox mounting using

new bolts -arrows-. Tightening torque ⇒ Item 12 (page 123)

WARNINGProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Do not remove support bracket -10 - 222 A- until all bolts se‐
curing the left-hand engine/gearbox mounting have been tight‐
ened to the specified torque.

– Check adjustment of assembly mountings; adjust if necessary

⇒ Engine, mechanics; Rep. gr. 10 .

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 115
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Fit pendulum support with new bolts -1 … 3- in accordance

with installation instructions ⇒ page 127 . Tightening torques
⇒ page 122
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– If removed earlier, bolt on heat shield for drive shaft (right-
side).

– Attach connector -1-.

– Install strut -A-. Tighten bolts -2- and -3- and secure exhaust
system ⇒ Engine, mechanics; Rep. gr. 26 .

– Fit air intake hose (left side). When installing air pipes with
plug-in connections, make sure retaining clip -arrow- snaps
onto retaining lug -A-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install clutch slave cylinder -arrows-. Tightening torque
⇒ Item 9 (page 41)
– Install gearbox support -1-. Tightening torque
⇒ Item 1 (page 122)
– Install starter ⇒ Electrical system; Rep. gr. 27 .

116 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Gearbox for vehicles with start/stop system: plug connector

-arrow- into gearbox neutral position sender -G701- .

– Plug in electrical connector -arrow- at reversing light switch -

F4- .
– Connect earth strap at upper engine/gearbox securing bolt.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Metal relay lever -B-:

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– If previously removed, install gearbox selector lever -A-

⇒ page 74 .
– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 73) .
– Insert relay lever -B- and secure with securing clip -arrow 3-.
– Attach gear selector cable to gearbox selector lever and se‐
cure with securing clip -arrow 1-.
– Attach gate selector cable to relay lever and secure with se‐
curing clip -arrow 2-.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 117
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Plastic relay lever:

– Insert relay lever with cable end-piece as far as stop.
• Relay lever is secured by detent -arrow 1-.
• Cable end-piece is secured by detent -arrow 2-.
• Ensure that components engage securely.

Note

From 08.2008 onwards the relay lever is secured with a clip

⇒ page 31 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Continued for all vehicles:

– Secure cable support bracket -arrows-. Tightening torque
⇒ Item 6 (page 72)
– Fit bracket -B- to gearbox. Tightening torque
⇒ Item 19 (page 28)
– Push pipe/hose assembly -A- into bracket -B- on gearbox.
– Adjust selector mechanism ⇒ page 82 .

– Install battery tray -arrows- and battery ⇒ Electrical system;

Rep. gr. 27 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .

118 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Install front section of wheel housing liner (left-side) ⇒ General

body repairs, exterior; Rep. gr. 66 .
– Fit front left wheel ⇒ Rep. gr. 44 .

Audi A3
– Install noise insulation (centre) ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .

Audi A3 Cabriolet
– Install noise insulation frame -arrow- ⇒ General body repairs,
exterior; Rep. gr. 50 .

– Install noise insulation (centre) -1- ⇒ General body repairs,

exterior; Rep. gr. 50 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Removing and installing gearbox - vehicles with 1.9 ltr. TDI engine 119
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Tightening torques
Engine/gearbox securing bolts
Item Bolt Qty. Nm
1 M 12 x 55 1 80
2 M 12 x 55 1 80
3 1)2) M 12 x 150 1 80
4 1)2) M 12 x 150 1 80
5 M 10 x 50 3 40
6 M 12 x 60 1 80
A Dowel sleeves for 2
centralising
• 1) Bolt with stud M8.
• 2) Also starter to gearbox

Component Nm
Small cover plate for flywheel 10
Bracket for electrical wiring at bottom starter bolt 23
Heat shield for drive shaft to cylinder block, M10 25

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

120 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

4 Transporting gearbox
Special tools and workshop equipment required
♦ Gearbox lifting tackle -3336-

♦ Workshop hoist -VAS 6100-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Bolt gearbox lifting tackle -3336- to clutch housing.

– Set support arm on sliding bracket by means of locking pin

-arrow-.
Number of holes visible = 5
– Lift gearbox with workshop hoist -VAS 6100- and gearbox lift‐
ing tackle -3336- .
– Set down gearbox as required (for example in transport con‐
tainer).

4. Transporting gearbox 121

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

5 Exploded view - assembly mountings

1 - Bolt
❑ 20 Nm + 90°
❑ Gearbox support to
gearbox and gearbox
bracket
❑ Tightening sequence
⇒ page 123
❑ Always renew
2 - Gearbox support
❑ To gearbox bracket and
gearbox
3 - Engine mounting with en‐
gine support
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 10
❑ Tightening torques ⇒
Engine, mechanics;
Rep. gr. 10
4 - Bolt
❑ 100 Nm + 90°
❑ Pendulum support to
subframe
❑ Always renew
5 - Pendulum support
❑ Removing and installing
⇒ page 126
6 - Bolt
❑ 50 Nm + 90°
❑ Pendulum support to
gearbox
❑ Always renew
7 - Bolt
❑ 50 Nm + 90°
❑ Pendulum support to gearbox
❑ Always
Protected renew
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
8 - Bolt
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ 40 Nm + 90°
❑ Gearbox bracket to gearbox
❑ Always renew
9 - Gearbox bracket
❑ Removing and installing ⇒ page 127
10 - Gearbox mounting
❑ Removing and installing ⇒ page 123
❑ Attach to gearbox bracket
11 - Bolt
❑ 40 Nm + 90°
❑ Gearbox mounting to body

122 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

❑ Tightening sequence ⇒ page 123

❑ Always renew
12 - Bolt
❑ 60 Nm + 90°
❑ Gearbox mounting to gearbox bracket
❑ Always renew

Attaching gearbox mounting to gearbox bracket

– Renew bolts -arrows-
– Tighten all bolts hand-tight.
– Tighten bolts to specified torque.

Gearbox support to gearbox bracket and gearbox

– Renew bolts.
– Initially tighten both bolts -arrows- hand-tight.
– Tighten bolts to specified torque.

5.1 Removing and installing gearbox

mounting
Special tools and workshop equipment required
♦ Support bracket -10 - 222 A-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Exploded view - assembly mountings 123

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery ⇒ Electrical system; Rep. gr. 27 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press release tab -arrow- and remove coverpermitted
-1- over battery.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– With ignition switched off, disconnect and remove battery ⇒
Electrical system; Rep. gr. 27 .
– Remove air cleaner housing ⇒ Rep. gr. 23 .

– Remove bolts -arrows- and take out battery tray -1- .

– Remove engine cover panel ⇒ Engine, mechanics; Rep. gr.

10 .
– Set up support bracket -10 - 222 A- with adapters -10 - 222 A /
1- on wing mounting flanges.
– Engage hook of spindle -10 - 222 A /11- in engine lifting eye.
– Take up weight of engine evenly with spindle; do not lift.

124 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove bolts -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open retainers permitted
for wiring
unlessduct -arrows-.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Cut open cable tie -1- and push electrical wiring to one side.
– Unclip wiring duct.

– Remove bolts -1- and detach gearbox mounting -A-.

Installing
Installation is carried out in reverse sequence; note the following:
• Tightening torques ⇒ page 122
– Fit gearbox mounting -A- with new bolts -1- to longitudinal
member. Tightening torque ⇒ Item 11 (page 122)

5. Exploded view - assembly mountings 125

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Caution

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, push the gearbox up at
the rear with a trolley jack.

– Pull gearbox up with spindle on support bracket -10 - 222 A-

until gearbox bracket contacts support arm of gearbox mount‐
ing.
– Bolt support arm of gearbox mounting onto gearbox bracket
using Protected
new bolts -arrows-. Tightening torque
⇒ Itempermitted
12 (pageunless123)
by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Adjust assembly mountings ⇒ Engine, mechanics; Rep. gr.

with respect to the correctness of information in this document. Copyright by AUDI AG.

10 .
– Detach support bracket -10 - 222 A- from engine.
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install air cleaner housing ⇒ Rep. gr. 23 .
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .

5.2 Removing and installing pendulum sup‐

port
– Remove noise insulation (centre) -1- ⇒ General body repairs,
exterior; Rep. gr. 50 .

126 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Unscrew bolts -1 ... 3- and remove pendulum support.

Installing pendulum support
Installation is carried out in reverse sequence; note the following:
• Tightening torques ⇒ page 122

– First secure pendulum support to gearbox -arrow B- and

-arrow C-, then on subframe -arrow A-.
– Install noise insulation (centre) ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .

5.3 Removing and installing gearbox brack‐

et
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment
permitted unless authorised by required
AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Support bracket -10 - 222 A-

Removing

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery ⇒ Electrical system; Rep. gr. 27 .

5. Exploded view - assembly mountings 127

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Press release tab -arrow- and remove cover -1- over battery.
– With ignition switched off, disconnect and remove battery ⇒
Electrical system; Rep. gr. 27 .
– Remove engine cover panel ⇒ Engine, mechanics; Rep. gr.
10 .
– Remove air cleaner housing ⇒ Rep. gr. 23 .

– Remove bolts -arrows- and take out battery tray -1- .

– Set up support bracket -10 - 222 A- with adapters -10 - 222 A /

1- on wing mounting flanges.
– Engage hook of spindle -10 - 222 A /11- in engine lifting eye.
– Take up weight of engine evenly with spindle; do not lift.

– Remove gearbox support -arrows-.

– Raise vehicle.
– Remove front left wheel.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Turn steering to the left.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

128 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove noise insulation (centre) by releasing fasteners

-1 ... 3-.

– Remove front section of wheel housing liner (left-side)

-fasteners 1 ... 3-.

– Remove bolts -1 ... 3- and detach pendulum support.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove bolts -arrows- at left mounting from gearbox mount‐

ing.

5. Exploded view - assembly mountings 129

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Adjust spindles of support bracket -10 - 222 A- to lower gear‐

box by distance -a-.
• Dimension -a- = 50 mm

– Unbolt gearbox bracket -A- from gearbox -arrows- and detach.

Installing
Installation is carried out in reverse sequence; note the following:
– Fit gearbox bracket -A- with new bolts -arrows-. Tightening
torque ⇒ Item 8 (page 122)

Caution

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, push the gearbox up at
the rear with a trolley jack.
♦ Do not remove support bracket 10-222A until the bolts se‐
curing the engine/gearbox mounting -arrows- have been
tightened to the specified torque.

– Pull gearbox up with spindle on support bracket -10 - 222 A-

until gearbox bracket contacts support arm of gearbox mount‐
ing.
– Bolt support arm of gearbox mounting onto gearbox bracket
using new bolts -arrows-. Tightening torque
⇒ Item 12 (page 123)
– Adjust assembly mountings ⇒ Engine, mechanics; Rep. gr.
10 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach support bracketpermitted
-10 - 222 A- from engine.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

130 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– First bolt pendulum support onto gearbox -bolts 2 … 3- and

then secure to subframe -bolt 1- (use new bolts). Tightening
torques ⇒ page 122

– Install front section of wheel housing liner (left-side) ⇒ General

body repairs, exterior; Rep. gr. 66 .
– Install noise insulation (centre) ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .
– Fit front left wheel ⇒ Rep. gr. 44 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install air cleaner housing ⇒ Rep. gr. 23 .
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Exploded view - assembly mountings 131

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

6 Checking gear oil level and filling up

with gear oil

Caution

It is not possible to check the gear oil level by removing the oil
filler plug.

Due to the inclination of the engine/gearbox assembly, the oil lev‐

el -arrow 2- will be above the lower edge of the filler hole
-arrow 1-.
The gear oil level can only be checked by draining the gear oil
completely and then filling up again.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Carry out the steps described in the chapters specified below in
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

the following order:

with respect to the correctness of information in this document. Copyright by AUDI AG.

• ⇒ „6.1 Preparations“, page 132

• ⇒ „6.2 Draining off gear oil“, page 133
• ⇒ „6.3 Filling up with gear oil“, page 134

Special tools and workshop equipment required

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ Hose (length approx. 600 mm, outside diameter 10 mm) with

funnel (commercially available)

6.1 Preparations
Gear oil specification for manual gearboxes ⇒ Electronic parts
catalogue
– Remove complete air cleaner housing ⇒ Rep. gr. 23 .

132 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Audi A3
– Remove noise insulation (centre) by releasing fasteners
-1 ... 3-.

Audi A3 Cabriolet
– Remove noise insulation (centre) -1- ⇒ General body repairs,
exterior; Rep. gr. 50 .
Continued for all vehicles
Clean gearbox.

Caution

A pivot pin for the selector forks in the gearbox must be re‐
moved in order to drain the gear oil.
The selector shaft must be locked to prevent the position of the
selector forks from being changed, e.g. due to accidental op‐
eration
Protected of the Copying
by copyright. selector mechanism.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Lock the selector shaft as follows:

– Press selector shaft down (direction of -arrow 1-).

– While pressing selector shaft down, move angled rod -A- up‐
wards in direction of -arrow 2-. At the same time press angled
rod carefully into selector shaft until it engages.

6.2 Draining off gear oil

Use a clean container (capacity 3.0 ltr.) with a graduated scale to
collect gear oil.
• Selector shaft must be locked ⇒ page 133 .

6. Checking gear oil level and filling up with gear oil 133
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove oil drain plug -arrow 1-, then remove pivot pin
-arrow 2- and drain off gear oil.
– Install pivot pin -arrow 2- with a new O-ring
⇒ Item 7 (page 139) .

– Fit oil drain plug -arrow 1- ⇒ Item 17 (page 165) .

– Now turn angled rod -A- back to original position (direction of
-arrow-) so that selector shaft can move freely again.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6.3 Filling up with gear oil

Add gear oil to container until amount of gear oil in container is
1.7 ltr.
Gear oil specification for manual gearboxes ⇒ Electronic parts
catalogue
– Remove reversing light switch -F4- -arrow-.
– Fit hose (length approx. 600 mm, outside diameter 10 mm) to
funnel (commercially available)
– Insert hose in mounting hole of reversing light switch and fill
gearbox with gear oil.
– Re-install reversing light switch -F4- -arrow-. Tightening torque
⇒ Item 2 (page 171)
– Check operation of selector mechanism ⇒ page 85 .
– Install complete air cleaner housing ⇒ Rep. gr. 23 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 .

134 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

7 Dismantling and assembling gearbox

♦ ⇒ „7.1 General layout of gearbox“, page 135
♦ ⇒ „7.2 Exploded view“, page 136
♦ ⇒ „7.3 Exploded view - removing and installing gearbox hous‐
ing cover and 5th gear“, page 137
♦ ⇒ „7.4 Exploded view - removing and installing gearbox hous‐
ing and selector mechanism“, page 139
♦ ⇒ „7.5 Exploded view - removing and installing input shaft,
output shaft, differential and selector forks“, page 140
♦ ⇒ „7.6 Assembly sequence - removing and installing gearbox
housing cover and 5th gear“, page 141
♦ ⇒ „8 Assembly sequence - dismantling and assembling com‐
plete gearbox“, page 147

7.1 General layout of gearbox

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Selector mechanism
❑ (Selector forks)
9 - Reverse gear wheel
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Dismantling and assembling gearbox 135

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

7.2 Exploded view

Assembly sequence - removing and installing gearbox housing
cover and 5th gear ⇒ page 141
Assembly sequence - dismantling and assembling complete
gearbox ⇒ page 147

I - Removing and installing

gearbox housing cover and
5th gear ⇒ page 137
II - Removing and installing
gearbox housing and selector
mechanism ⇒ page 139
III - Removing and installing in‐
put shaft, output shaft, differ‐
ential and selector forks
⇒ page 140

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

136 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

7.3 Exploded view - removing and installing gearbox housing cover and
5th gear

1 - Bolt
❑ 18 Nm
❑ For gearbox housing
cover
2 - Gearbox housing cover
❑ From 11.2010 onwards:
with magnet
⇒ page 138

Note

♦ If gearbox housing cover is de‐

tached and re-fitted with gearbox
installed in vehicle, drain off gear
oil and refill ⇒ page 132
♦ Please note that a small amount
of residual oil will emerge when
the cover is detached.

3 - Gasket
4 - Bolt
❑ 80 Nm + 90°
❑ Always renew
❑ Fitted piece on bolt head
holds dished spring in
position
❑ Use thread
Protected tapCopying
by copyright. to re‐for private or commercial purposes, in part or in whole, is not
move unless
permitted any remaining
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
locking fluid from threa‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

ded holes for bolts se‐

curing synchro-hub and
5th gear wheel. Other‐
wise there is a risk that
the bolts will shear off.
5 - Dished spring
❑ Installing ⇒ page 160
6 - Socket head bolt
❑ 25 Nm
❑ For pivot pin to gearbox housing
7 - Pivot pin
8 - 5th gear selector fork
❑ Dismantling and assembling ⇒ page 175
❑ Adjusting ⇒ page 161
9 - Spring
❑ Offset version
❑ Installing ⇒ page 187
10 - 5th gear locking collar
❑ Installation position ⇒ page 187
❑ Adjusting ⇒ page 161

7. Dismantling and assembling gearbox 137

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

11 - Locking pieces (3x)

❑ Installation position ⇒ page 187
12 - Synchro-hub with 5th speed selector gear and synchro-ring
❑ Dismantling and assembling ⇒ page 187
13 - Needle bearing
❑ For 5th speed selector gear
14 - 5th gear wheel
❑ Pulling off individually ⇒ page 141
❑ Pulling off together with gearbox housing ⇒ page 147
❑ Installation position ⇒ page 159
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Gearbox housing cover with magnet -A-
The magnet can only be fitted in a cover with a recess -arrow-.
When the cover is installed, the magnet is held in position by the
securing bolt for the pivot pin for the 5th gear selector fork.

138 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

7.4 Exploded view - removing and installing gearbox housing and selector
mechanism

1 - Countersunk bolt
❑ 25 Nm
2 - Flange shaft with spring
❑ Removing and installing
⇒ page 213
❑ Assembling
⇒ page 227
3 - Torx socket head bolt
❑ 25 Nm
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Always renew
4 - Torx socket head bolt
❑ 30 Nm
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Always renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - O-ring with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Always renew
6 - Pivot pin
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 25 Nm
9 - Cover plate
10 - Multi-point socket head
bolt
❑ 25 Nm
❑ For reverse shaft support
❑ Always renew
11 - Bolt
❑ 5 Nm
12 - Gearbox neutral position sender -G701-
❑ For vehicles with start/stop system
❑ Removing and installing ⇒ page 169
13 - Gearbox housing
❑ Pulling off together with 5th gear ⇒ page 147
❑ Servicing ⇒ page 162
14 - Clutch housing
❑ Servicing ⇒ page 162
15 - Hexagon bolt
❑ 25 Nm + 90°

7. Dismantling and assembling gearbox 139

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

16 - Selector shaft with selector mechanism cover

❑ (Selector unit)
❑ Servicing ⇒ page 171
17 - Bolt
❑ 25 Nm

7.5 Exploded view - removing and installing input shaft, output shaft, differential
and selector forks

1 - Differential Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Dismantling and assem‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
bling ⇒ page 227 with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Seal
❑ 4x
❑ Always renew
3 - Output shaft
❑ Dismantling and assem‐
bling ⇒ page 193
4 - Reverse shaft support
❑ Dismantling and assem‐
bling ⇒ page 210
5 - Reverse shaft
❑ Dismantling and assem‐
bling ⇒ page 210
6 - Input shaft
❑ Dismantling and assem‐
bling ⇒ page 180
7 - Reverse gear selector fork
❑ Dismantling and assem‐
bling ⇒ page 175
❑ Installation position
⇒ page 155
8 - Torx socket head bolt
❑ 25 Nm
9 - Selector mechanism
❑ (Selector forks)
❑ Dismantling and assem‐
bling ⇒ page 175
10 - Clutch housing
❑ Servicing ⇒ page 162
11 - Nut
❑ 25 Nm + 90°
❑ 4 nuts for bearing mounting
❑ Renew
12 - Flange shaft with spring
❑ Removing and installing ⇒ page 213
❑ Assembling ⇒ page 227

140 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

13 - Countersunk bolt
❑ 25 Nm

7.6 Assembly sequence - removing and in‐

stalling gearbox housing cover and
5th gear

Note

♦ If only the 5th gear has to be removed, please refer to the work
sequence described below.
♦ If the gearbox housing has to be removed, please refer to the
assembly sequence: Dismantling and assembling complete
gearbox ⇒ page 147 .

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Driftpermitted
-VW 295- unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Drift sleeve -VW 244 B-
♦ Hot air blower -V.A.G 1416-
♦ Torque wrench -V.A.G
1331-

7. Dismantling and assembling gearbox 141

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Support bridge -30-211A-

♦ Thrust piece -32 - 111-
♦ Thrust piece -T10030/4- of
assembly tool -T10030-
♦ Tube -VW 416 B-
♦ Puller -T10309-
♦ Two-arm puller -T10040-
♦ With claws -T10040/2A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

142 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Support bridge -T10323-

♦ Assembly tool -3253/7-
♦ Press tool -VW 433-
♦ Torque wrench -V.A.G
1332-

Removing
– Remove clutch release lever and release bearing ⇒ page 41 .
• The bearings of the input shaft and output shaft must not be
damaged when removing and installing 5th gear.
• For this reason, when attaching the gearbox to gearbox sup‐
port -VW 353- , you must first attach the following tools to
provide the necessary support:
Below input shaft:
♦ Support bridge -30-211A-
♦ Thrust piece -32Protected
- 111-by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

♦ Thrust piece -T10030/4-

with respect to the correctness of information in this document. Copyright by AUDI AG.

• The input shaft should not be supported by the thrust piece

-32 - 111- until it becomes necessary later on.
Below bearing mounting for output shaft:
♦ Support bridge -T10323-
♦ Assembly tool -3253/7-
♦ Press tool -VW 433-

7. Dismantling and assembling gearbox 143

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Secure gearbox on gearbox support -VW 353- .

– Unbolt gearbox housing cover -arrow-.

– Check whether claws -T10040/2A- can be applied correctly

below 5th gear wheel.
If claws -T10040/2A- cannot be applied correctly:
-A- In this case the 5th gear
Claws -T10040/2A- foul against: synchro-hub, 5th gear
♦ side of gearbox housing wheel and gearbox housing
have to be removed togeth‐
♦ ribs in gearbox housing below er ⇒ page 147 .
gear wheel

-B-
Claws -T10040/2A- foul against
ribs in gearbox housing below 5th
gear wheel.

If claws -T10040/2A- can be applied correctly:

5th gear can be removed separately ⇒ page 144

Removing 5th gear separately

– Cover openings in gearbox housing with a cloth.
– Move selector fork -1- to neutral.
– Unscrew bolt -2- with
Protected 5th gear
by copyright. selector
Copying jaw.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Then removewith
both bolts
respect to the-arrows- forinformation
correctness of pivot pins.
in this document. Copyright by AUDI AG.

– Pull out pivot pins.

– Take out selector fork.
– Spring -3- and locking collar -4- do not have to be removed.

144 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove bolts -A- for synchro-hub and 5th gear wheel; to do

this engage 5th gear -arrow 1- and 1st gear -arrows 2- and
-3-
.
– After engaging both gears the input shaft and output shaft are
locked; the synchro-hub and gear wheel cannot turn. The two
bolts can now be loosened.

Note

If the shafts are not being renewed, carefully clean residual lock‐
ing compound out of tapped holes using a thread tap.

Pulling off synchro-hub for 5th gear together with locking collar
and locking pieces
Use puller -T10309- .
– First insert shell half -T10309/1- between 5th gear wheel -A-
and mounting for 5th gear selector fork -B-.

• Shell half -T10309/1- must be positioned underneath synchro-

ring.
– If necessary, press shell half into end position.
– Then turn shell half -T10309/1- to opposite side in direction of
-arrow-.

– Introduce thread insert -T10309/3- into shell half .

– Now fit second shell half -T10309/1- and slide tube -T10309/2-
onto tool.
– Please check synchro-hub for damage after removal.
– Renew synchro-ring for 5th gear.
– Remove 5th speed selector gear with needle bearing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Dismantling and assembling gearbox 145

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Pull off 5th gear wheel.

– First fit claws -A-.
B - Thrust piece -T10040/3- or hexagon bolt (M10 x 20), 17 mm

Note

♦ Ensure that the claws do not bend outwards when pulling off
the gear wheel. Check 5th gear wheel for damage after re‐
moval.
♦ If necessary, heat 5th gear wheel using hot air blower -V.A.G
1416- before pulling off.

Installing
Installing 5th gear ⇒ bypage
Protected 158Copying
copyright. . for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install gearbox
with housing
respect to thecover ⇒ page
correctness 137 in. this document. Copyright by AUDI AG.
of information

– Install clutch release lever and release bearing ⇒ page 41 .

– Fill up gear oil ⇒ page 111 .

146 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

8 Assembly sequence - dismantling and assembling complete gearbox

Removing and installing cover for gearbox housing, clutch hous‐
ing, selector shaft with selector mechanism cover, input shaft,
output shaft, differential and selector mechanism

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
♦ Drift -VW 295-
♦ Drift sleeve -VW 244 B-
♦ Hot air blower -V.A.G 1416-
♦ Torque wrench -
V.A.G 1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Assembly sequence - dismantling and assembling complete gearbox 147

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Support bridge -30-211A-

♦ Thrust piece -32 - 111-
♦ Thrust piece -T10030/4- of
assembly tool -T10030-
♦ Tube -VW 416 B-
♦ Puller plate -T10408-
♦ Thrust blocks -T10408/2-
♦ Hexagon bolts M7 x 35 with
washers (component parts
of puller plate -T10408- )

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

148 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Support bridge -T10323-

♦ Assembly tool -3253/7-
♦ Press tool -VW 433-
♦ Torque wrench -V.A.G
1332-

♦ -2- Puller -Kukko 18/1- (2x)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Assembly sequence - dismantling and assembling complete gearbox 149

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Inductive heater -VAS 6414-

♦ Stud M8 x 100 mm

8.1 Dismantling complete gearbox

– Secure gearbox on gearbox support -VW 353- .
– Place drip tray underneath.
– Unscrew oil filler plug and oil drain plug.
– Drain off gear oil.
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 41 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

• The bearings of the input shaft and output shaft must not be
damaged when removing and installing 5th gear.
• For this reason, when attaching the gearbox to gearbox sup‐
port -VW 353- , you must first attach the following tools to
provide the necessary support:
Below input shaft:
♦ Support bridge -30-211A-
♦ Thrust piece -32 - 111-
♦ Thrust piece -T10030/4-
– Secure bolt of support bridge -30-211A- with lock nut -A-.
Below bearing mounting for output shaft:
♦ Support bridge -T10323-
♦ Assembly tool -3253/7-
♦ Press tool -VW 433-

150 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Unbolt gearbox housing cover -arrow-.

Remove 5th gear selector fork as follows:

– Move selector fork -1- to neutral.
– Unscrew bolt -2- with 5th gear selector jaw.
– Then remove both bolts -arrows- for pivot pins.
– Pull out pivot pins.
– Take out selector fork.
– Spring -3- and locking collar -4- do not have to be removed.

– Remove bolts -A- for synchro-hub and 5th gear wheel, to do

this select 5th gear -arrow 1- and 1st gear -arrows 2- and -3-.
– After engaging both gears the input shaft and output shaft are
locked; the synchro-hub and gear wheel cannot turn. The two
bolts can now be loosened.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
If the shafts are not being renewed, carefully clean residual lock‐
ing compound out of tapped holes using a thread tap.

– Remove both bolts -arrows- for reverse shaft support.

8. Assembly sequence - dismantling and assembling complete gearbox 151

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Now remove 3rd bolt -arrow- for reverse shaft support.

– Gearbox for vehicles with start/stop system: remove gearbox

neutral position sender -G701- -arrow-.

– Remove selector shaft with selector mechanism cover. To do

this, set selector shaft in neutral position. Then remove bolts
-arrows- and pull selector shaft out of gearbox housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.

152 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove pivot pins -A- on top side of gearbox and bolts -B-
securing gearbox housing to clutch housing (near differential).

– Remove bolts -A- securing gearbox housing from inside clutch

housing.

Note

Do not remove nuts -B- for output shaft bearing mounting.

– Remove both flange shafts.

– Take out flange shafts together with springs, thrust washers
and tapered rings.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Assembly sequence - dismantling and assembling complete gearbox 153

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pull off the following components, together with the gearbox

housing:
♦ 5th gear synchro-hub
♦ 5th gear wheel
• You must secure the two brackets -T10408/3- to the 5th gear
wheel.
• Always position the brackets above 2 opposite ribs on the
housing -arrows-.

Caution

Risk of damage to needle bearing for output shaft in gearbox

housing
• A needle bearing is located underneath the 5th gear wheel
in the gearbox housing.
• Please secure the two brackets . This will prevent the
needle bearing from coming into contact with the 5th gear
wheel when the gearbox housing is pulled off.

Use puller plate -T10408- together with the following special tools:
♦ Thrust blocks -T10408/2-
♦ Brackets -T10408/3-
♦ Puller Kukko 18/1 (2x)
– Bolt on puller plate -T10408- using threaded holes for gearbox
housing cover.
A - Hexagon bolts M7 x 35 with washers
Tightening torque: 18 Nm
– Fit thrust blocks -T10408/2- on shafts.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach pullers
permitted Kukko by18/1
unless authorised AUDI .AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull off 5th gear synchro-hub, 5th gear wheel and gearbox
housing by tightening spindles -A- of pullers Kukko 18/1 alter‐
nately, 1/2 turn at a time.
– If necessary, heat 5th gear wheel using hot air blower -
V.A.G 1416- before pulling off.

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 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove selector forks -A- together with selector plates.

– Unscrew bolt for reverse gear selector mechanism -B-.

– Remove nuts -B- for output shaft bearing mounting.

– Remove reverse gear -A-, input shaft-B- and output shaft -C-
one after the other from clutch housing.
– Take out differential.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8.2 Assembling gearbox

– Fit differential.
– Always renew seals -arrows- for output shaft bearing mount‐
ing.

Note

The illustration only shows 3 of the 4 seals.

8. Assembly sequence - dismantling and assembling complete gearbox 155

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Insert input shaft -1- and output shaft -2- together.

– Tighten nuts for output shaft bearing mounting to torque
⇒ Item 11 (page 140) .
– Place reverse gear wheel -3- on needle bearing in clutch
housing.
Shoulder -arrow- faces away from clutch housing.
– Check that reverse shaft -4- is complete ⇒ page 210 ; do not
fit reverse shaft support onto reverse shaft yet.
– Insert reverse shaft in clutch housing.
– Clean locking fluid residue from all tapped holes in reverse
shaft support (residue can be removed using a tap).
– Install reverse shaft support.

– Fit reverse gear selector fork -1- with support for reverse gear
selector fork -2-, spring -3- and slide -4-.

Installation position: reverse gear

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tighten bolt for reverse gear selector mechanism -A-.

– Install selector forks -B- together with selector plates.
Pin on reverse shaft support -C- is located in front of selector
plates.

156 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Screw M8 x 100 mm stud -A- into reverse shaft support so that

support is aligned after fitting gearbox housing.
– Align selector plates.

Note

The detent segments must be positioned in the grooves on the

locking collars.

– Apply sealant -AMV 188 200 03- evenly to sealing surface of

clutch housing.
– Fit and secure gearbox housing. Tightening torque
⇒ Item 15 (page 139)
Install bolts for reverse shaft support -arrow- as follows:
– Fit bolt -a-.
– Remove stud -A- (⇒ top illustration).

– Fit bolt -c-.

Tightening sequence:
– Tighten bolt -a- to 30 Nm.
– Tighten bolt -b- (⇒ bottom illustration) to 25 Nm.

– Tighten bolt -c- to 25 Nm.

– Install pivot pins -arrow- for selector forks. To do this align se‐
lector mechanism using a screwdriver so that the relevant
pivot pin can be inserted.
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
cover plate.
– Fit cover plate for selector shaft.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Assembly sequence - dismantling and assembling complete gearbox 157

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Install selector shaft and selector mechanism cover as follows:

– Set selector plates in neutral position.
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
selector mechanism cover.
– Put selector shaft in neutral position.
– Position selector shaft so that selector finger -arrow- is en‐
gaged in selector plates.
– Tighten selector mechanism cover to specified torque
⇒ Item 17 (page
Protected140) .
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Gearbox for vehicles with start/stop system: fit gearbox neutral

position sender -G701- -arrow- and tighten securing bolt to
specified torque ⇒ Item 11 (page 139) .

– Install both flange shafts with springs, thrust washers and ta‐
pered rings. Tightening torque ⇒ Item 12 (page 230)

Install 5th gear as follows:

• Please ensure that the support bridge -30-211A- and support
bridge -T10323- are fitted.
– Secure bolt of support bridge -30-211A- with lock nut -A-.

158 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installation position of 5th gear wheel

The groove running round the gear wheel -arrow- faces to the
gearbox housing.

– Heat 5th gear wheel and drive on.

WARNING

Wear protective gloves.

Checking 5th gear synchro-ring

– Before re-installing selector gear and synchro-ring for
5th gear, press the synchro-ring onto the tapered seat of the
selector gear and measure gap -a- with a feeler gauge.
Gap -a- Installation depth Wear limit
5th gear 1.1 ... 1.7 mm 0.5 mm
– Install 5th speed selector gear with needle bearing.
– Fit 5th gear synchro-ring on selector gear.
– If previously dismantled, assemble 5th gear synchro-hub/lock‐
ing collar before installing ⇒ page 187 .

Installation position of 5th gear synchro-hub/locking collar

The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchro-hub -arrow 2- face the gearbox housing.
Retainers -arrow 3- in synchro-hub align with cast locking pieces
on synchro-ring (arrows in ⇒ page 160 below).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Assembly sequence - dismantling and assembling complete gearbox 159

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

5th gear synchro-ring with cast locking pieces -arrows-

– Cover all openings with a cloth to prevent dirt etc. from entering
the gearbox.

– Heat 5th gear synchro-hub and drive on.

WARNING

Wear protective gloves.

Note

When driving on, ensure clearance for synchro-ring.

– Loosen support for input shaft.

– If not already done, use thread tap to remove any remaining
locking fluid from threaded holes for bolts securing synchro-
hub and 5th gear wheel.
Otherwise there is a risk that the bolts will shear off.
– Screw in new securing bolts for synchro-hub and 5th gear
wheel.

Installation position of dished springs for securing bolts for 5th

gear wheel and synchro-hub
Concave side -arrows- faces 5th gear.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

160 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Tighten bolts -A- for synchro-hub and 5th gear wheel to speci‐
fied torque ⇒ Item 4 (page 137) ; to do this select 5th gear
-arrow 1- and 1st gear -arrows 2- and -3-.
– After engaging both gears the input shaft and output shaft are
locked; the synchro-hub and gear wheel cannot turn. The two
bolts can now be tightened.
– Install 5th gear selector fork.

Adjusting 5th gear

– Engage 5th gear. Loosen bolt -1-. Press locking collar and se‐
lector jaws in direction of -arrow-,
Protected then tighten
by copyright. Copying forbolt
private-1- to 25 purposes, in part or in whole, is not
or commercial
Nm. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Check adjustment: It should not be possible to slide a 0.2 mm
feeler gauge between locking collar and selector gear. Repeat
adjustment if necessary.
– Disengage 5th gear. Locking collar should now be in the neu‐
tral position. Synchro-ring should move freely.
– Select all gears.
– Install gearbox housing cover ⇒ page 137 .
– Install release bearing guide sleeve ⇒ page 41 .
– Install clutch release lever and release bearing ⇒ page 41 .
– Fill up gear oil ⇒ page 94 .

8. Assembly sequence - dismantling and assembling complete gearbox 161

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

9 Exploded view - servicing gearbox housing and clutch housing

Special tools and workshop

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Thrust plate -VW 447 H-
♦ Thrust pad -VW 512-
♦ Press tool -VW 454-
♦ Tube -2040-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

162 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Puller -VW 228 B- (not used

on this gearbox)
♦ Drift -VW 222 A- (not used
on this gearbox)
♦ Assembly device -3066-
(assembly device spindle)
♦ Thrust piece -3124- (for
two-piece oil seal and
sleeve)
♦ Multi-purpose tool -
VW 771- (for one-piece oil
seal and sleeve)
♦ Puller hook -VW 771/37-
(for one-piece oil seal and
sleeve)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Thrust piece -T10148-
with respect (for one-piece
to the correctness of information oil seal
in this and Copyright
document. sleeve)by AUDI AG.

9. Exploded view - servicing gearbox housing and clutch housing 163

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Gearbox housing
❑ If renewed: Adjust input
shaft and differential
⇒ page 226
2 - Needle bearing
❑ For output shaft
❑ Removing ⇒ page 166
❑ Installing and securing
⇒ page 166
3 - Oil filler plug
❑ 35 Nm
❑ Gear oil level cannot be
checked by removing oil
filler plug
❑ If gearbox was disman‐
tled, fill with gear oil be‐
fore installing
❑ Capacity of manual
gearbox (gearbox com‐
pletely dismantled)
♦ 1.9 ltr.
❑ Capacity of manual
gearbox (gearbox parti‐
ally dismantled)
⇒ page 132
♦ 1.7 ltr.
4 - Tapered roller bearing outer
race
❑ For output shaft
❑ Removing and installing
⇒ page 193
❑ If renewed: Adjust out‐
put shaft ⇒ page 206
5 - Shim
❑ For output shaft
❑ Table of adjustments ⇒ page 226
6 - Shim
❑ For input shaft
❑ Table of adjustments ⇒ page 188
7 - Tapered roller bearing outer race
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For input shaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing ⇒ page 180 with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ If renewed: Adjust input shaft ⇒ page 188

8 - Tapered roller bearing outer race
❑ For input shaft
❑ Removing and installing ⇒ page 180
❑ If renewed: Adjust input shaft ⇒ page 188
9 - Needle bearing
❑ Removing and installing ⇒ page 210
10 - Dowel sleeve
❑ 2x

164 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

11 - Clutch housing
❑ If renewed: ⇒ table of adjustments ⇒ page 226
12 - Guide sleeve
❑ With input shaft oil seal and vulcanised O-ring
❑ Driving out oil seal ⇒ page 166
❑ Driving in oil seal ⇒ page 166
❑ Remove guide sleeve in order to renew oil seal
❑ Renew guide sleeve if O-ring is damaged
13 - Socket head bolt
❑ 20 Nm
14 - Oil seal
❑ Renewing ⇒ „1.3 Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve“, page 216
15 - Sleeve
❑ For oil seal ⇒ Item 14 (page 165)
❑ Removing ⇒ page 167
❑ Installing ⇒ page 167
16 - One-piece oil seal and sleeve
❑ If oil seal is damaged, renew both sleeve and oil seal
❑ Removing ⇒ page 167
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Installing ⇒ page 167respect to the correctness of information in this document. Copyright by AUDI AG.
with

17 - Oil drain plug

❑ 35 Nm
❑ Without magnet
18 - Tapered roller bearing outer race
❑ For differential
❑ Pressing out and pressing in ⇒ page 227
❑ If renewed: adjust differential ⇒ page 235
19 - Magnet
❑ Held in place by joint surface of housing
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 168
21 - Tapered roller bearing outer race
❑ For differential
❑ Pressing out and pressing in ⇒ page 227
❑ If renewed: adjust differential
⇒ page 235

22 - Shim
❑ For differential
❑ Table of adjustments ⇒ page 226
23 - Oil seal
❑ Renewing ⇒ „1.1 Renewing oil seal for flange shaft (left-side)“, page 213

9. Exploded view - servicing gearbox housing and clutch housing 165

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Driving out needle bearing

Driving in needle bearing onto stop

– Secure needle bearing in gearbox housing at three points
(120° offset) with a punch.

Driving oil seal out of guide sleeve

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Driving oil seal into guide sleeve (drive in onto stop)

166 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Lever out sleeve -arrow- with screwdriver

Installing sleeve
– Screw spindle -A- of assembly device -3066- into threaded
piece in differential.
– Turn nut -B- and pull sleeve in onto stop with thrust piece
-3124- .

Note

If gearbox has been dismantled, press in sleeve onto stop using

thrust piece -3124- .

Pulling out sleeve and oil seal

A shoulder is located on inside diameter of sleeve.
– To pull out oil seal and sleeve, apply puller hook -VW 771/37-
behind shoulder inside sleeve.
– During this operation, press puller hook -VW 771/37- firmly in
against sleeve.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Installing sleeve and oil seal
– Clean seat for oil seal in gearbox.
– Screw spindle -A- of assembly device -3066- into threaded
piece in differential.
– Turn nut -B- and pull sleeve in onto stop with thrust piece -
T10148- .

Note

If gearbox has been dismantled, press in sleeve onto stop using

thrust piece -T10148- .

9. Exploded view - servicing gearbox housing and clutch housing 167

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing oil collector -A- in gearbox housing

– Insert oil collector simultaneously into bore -arrow 1- and
groove -arrow 2-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

168 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

10 Removing and installing gearbox

neutral position sender -G701-
• Only in vehicles with start/stop system
• Gearbox installed
Removing
– Remove noise insulation -1- ⇒ General body repairs, exterior;
Rep. gr. 50 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unplug electrical connector -2- from gearbox neutral position

sender -G701- .

Note

Items marked -1- and -3- can be disregarded.

– Remove bolt -arrow- and pull out gearbox neutral position

sender -G701- -A-.

Note

Gearbox neutral position sender -G701- is shown with gearbox

removed.

Installing
– Install gearbox neutral position sender -G701- and tighten se‐
curing bolt -arrow- to specified torque ⇒ Item 11 (page 139) .

10. Removing and installing gearbox neutral position sender G701 169
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Plug in connector -arrow- at gearbox neutral position sender -

G701- .
– Install noise insulation (centre) -1- ⇒ General body repairs,
exterior; Rep. gr. 50 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

170 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

11 Exploded view - servicing selector unit

1 - Selector unit
❑ Consists of selector
shaft and selector
mechanism cover
❑ Components cannot be
separated from each
other
❑ Removing and installing
⇒ page 172
❑ Dismantling and assem‐
bling ⇒ page 173
2 - Reversing light switch -F4-
❑ 20 Nm
❑ Lightly coat lug with
MoS2 grease
3 - Locking pin
❑ For adjusting selector
mechanism
❑ Removing ⇒ page 173
❑ Pressing in
⇒ page 174
4 - Relay lever
❑ Installation position
⇒ page 74
❑ Plastic version from
model year 2008 on‐
wards
5 - Bearing bush
❑ Not required for plastic
relay lever
6 - Oil seal
❑ Lever out with screw‐
driver
❑ Installing ⇒ page 174
7 - Nut
❑ 23 Nm
❑ Self-locking
❑ Always renew
8Protected
- Gearbox selector
by copyright. Copyinglever
for private or commercial purposes, in part or in whole, is not
❑ Install
permitted so thatbygap
unless authorised AUDIin AG.splines aligns
AUDI AG does with selector
not guarantee shaft
or accept any ⇒ page 173
liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Can be renewed with selector mechanism installed
❑ Installation position ⇒ page 74
9 - Cap
❑ For gearbox breather
10 - Securing clip
❑ Always renew
❑ Not required for plastic relay lever

11. Exploded view - servicing selector unit 171

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

11 - Cover plate
12 - Spring
❑ Not fitted on all gearboxes
❑ If fitted, re-install

11.1 Removing and installing selector shaft

Removing
– Remove gearbox selector lever ⇒ Item 8 (page 171) .
– Put selector shaft in neutral position. Then remove bolts
-arrows- and pull selector shaft out of gearbox housing.
Installing

Install selector shaft and selector mechanism cover as follows:

– Set selector plates in neutral position.
– Apply sealing paste -AMV 188 200 03- evenly to sealing sur‐
face of selector mechanism cover.
– Put selector shaft in neutral position.
– Position selector shaft so that selector finger -arrow- is en‐
gaged in selector plates.

– Secure selector mechanism cover -arrows- (tightening torque:

25 Nm).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

172 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Install gearbox selector lever.

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11.2 Dismantling and assembling

Special tools and work‐
shop equipment re‐
quired
♦ Tube -T10203-

♦ Tube -VW 423-

Removing locking pin

-A- from selector mecha‐
nism cover
– Remove outer part of
retaining pin.
– Then lever out lock‐
ing pin carefully using
a screwdriver.

11. Exploded view - servicing selector unit 173

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing locking pin -A- into selector mechanism cover

Installation position:
Marking -arrow- points to upper section of selector shaft.

Installing oil seal (insert onto stop)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

174 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

12 Exploded view - dismantling and assembling selector forks

Special tools and workshop

equipment required
♦ Thrust plate -VW 402-
♦ Thrust piece -3290/1-
♦ Thrust piece -VW 431-
♦ Assembly tool -3301-
♦ Spacer sleeve -VW 472/2-
♦ Drift -10 - 206-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Removal lever -80–200-

12. Exploded view - dismantling and assembling selector forks 175

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Assembly mandrel -10 - 508-

♦ Tensioning device -2070-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

The selector fork cluster ( ⇒ Item 7 (page 177) ) does not have to be dismantled in order to remove and install
detent segments, lock washers and angular contact ball bearings.

176 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - 5th gear detent segment

❑ Identification
⇒ page 177
❑ Detent segment should
turn freely after lock
washer is installed
2 - Lock washer
❑ Always renew
❑ Removing ⇒ page 178
❑ Installing ⇒ page 178
3 - 5th gear selector fork
❑ Adjusting ⇒ page 161
4 - Bolt
❑ 25 Nm
5 - 5th gear selector jaw
6 - Angular contact ball bearing
❑ 4x
❑ Removing ⇒ page 178
❑ Pressing inner race into
outer race ⇒ page 178
❑ Installing ⇒ page 179
7 - Selector fork cluster with
selector plates
8 - 1st/2nd gear detent seg‐
ment
❑ Identification
⇒ page 177
❑ The segment must ro‐
tate freely after installing
the lock washer
9 - 3rd/4th gear detent segment
❑ Identification ⇒ page 177
❑ The segment must rotate freely after installing the lock washer
10 - Sliding piece
11 - Spring
12 - Reverse gear selector fork
13 - Support for reverse gear selector fork
14 - Circlip

Identification of detent segments

Dimension
Protected -a- Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1with
- Detent
respect tosegments,
the correctness 1st/2nd gear
of information in this=document.
11.4 mm Copyright by AUDI AG.

2 - Detent segments, 3rd/4th gear = 7.7 mm

3 - Detent segments, 5th gear = 12.1 mm

12. Exploded view - dismantling and assembling selector forks 177

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing lock washer

– Secure selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in direction of -arrow-.

Installing lock washer

– Push lock washer into groove in detent segment using socket
driver.

Note

Detent segment should turn freely after lock washer is installed.

A - Socket driver, 10 mm
B - Protective jaw covers

Removing angular contact ball bearing

Note

Do not bend selector forks when removing and installing the ball
bearing.

Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage positively in outer race.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

178 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pulling angular contact ball bearing into selector fork (insert onto
stop)
Recess in thrust piece -3290/1- points towards ball bearing.

Selector forks with detent segments installed

Dimension -a- (mm)
1st/2nd gear selector fork 87.2 … 87.4
3rd/4th gear selector fork 93.6 … 93.8
For identification of detent segments ⇒ page 177

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

12. Exploded view - dismantling and assembling selector forks 179

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

35 – Gears, shafts
1 Input shaft
⇒ „1.1 Exploded view - dismantling and assembling input shaft“,
page 180
⇒ „1.2 Adjusting input shaft“, page 188

1.1 Exploded view - dismantling and assembling input shaft

Special tools and workshop

equipment required
♦ Press tool -VW 407-
♦ Thrust plate -VW 447 H-
♦ Press tool -VW 412-
♦ Tube -VW 422-
♦ Thrust plate -VW 401-
♦ Press tool -VW 408 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

180 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Tube -VW 421-

♦ Thrust plate -VW 447 i-
♦ Press tool -VW 454-
♦ Thrust pad -VW 510-
♦ Drift sleeve -41-501-
♦ -3- Splitter -Kukko 17/1-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Thrust plate -VW 402-

1. Input shaft 181

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Inductive heater -VAS 6414-

Note

♦ Refer to general repair instructions ⇒ page 5 .

♦ Refer to technical data ⇒ page 1 and ⇒ Electronic parts catalogue when installing new gear wheels or a
new input shaft.
♦ The input shaft must be re-adjusted if the position of tapered roller bearings is affected when renewing parts.
Refer to table of adjustments ⇒ page 226 .

1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Pressing out Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 184 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Pressing in
with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 184
3 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 184
❑ Pressing on
⇒ page 184
4 - Input shaft
❑ Adjusting ⇒ page 188
5 - 3rd gear wheel
❑ Installation position:
Collar faces 4th gear
❑ Pressing off
⇒ page 185
❑ Pressing on
⇒ page 185
6 - Circlip
❑ Always renew
7 - 4th gear wheel
❑ Pressing off with ta‐
pered roller bearing out‐
er race and sleeve
⇒ page 185
❑ Pressing on
⇒ page 185

182 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

❑ Shoulder faces towards

3rd gear
8 - Tapered roller bearing inner race
❑ Pressing off with 4th gear wheel and sleeve ⇒ page 185
❑ Pressing on ⇒ page 186
9 - Thrust washer
10 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 186
❑ Pressing in ⇒ page 186
11 - Shim
❑ Determining thickness ⇒ page 188
12 - Gearbox housing
13 - Sleeve
❑ For 5th gear needle bearing
❑ Press off with 4th gear wheel and tapered roller bearing inner race ⇒ page 185
❑ Pressing on ⇒ page 186
❑ Fit thrust washer ⇒ Item 9 (page 183) before installing
14 - Needle bearing
❑ For 5th gear
15 - 5th speed selector gear
16 - 5th gear synchro-ring
❑ With cast locking pieces ⇒ page 160
❑ Checking for wear ⇒ page 159
17 - Spring
❑ Installation position ⇒ page 187
❑ Offset springs from gearbox build date 05 11 1 onwards ⇒ page 187
18 - Locking pieces (3x)
❑ Installation position ⇒ page 187
19 - 5th gear synchro-hub
❑ Pulling off individually ⇒ page 141
❑ Pulling off together with gearbox housing ⇒ page 147
20 - 5th gear locking collar
❑ Pull off together with 5th gear synchro-hub
21 - Dished spring
❑ Installation position ⇒ page 160
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
22 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Tightening torque ⇒ Item 4 (page 137)
❑ Always renew
❑ Fitted piece on bolt head holds dished spring in position ⇒ page 160

1. Input shaft 183

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race

A - Splitter 12 ... 75 mm -Kukko 17/1-

Pressing on tapered roller bearing inner race

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

184 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing off 4th gear wheel with tapered roller bearing and sleeve

Pressing off 3rd gear wheel

– First remove circlip.

Heat 3rd gear wheel and press on.

WARNING

Wear protective gloves.

Shoulder faces towards 4thProtected

gear. by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Heat 4th gear wheel and press on.

WARNING

Wear protective gloves.

Shoulder faces towards 3rd gear.

1. Input shaft 185

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing on tapered roller bearing inner race

Pressing on sleeve for 5th gear needle bearing

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

– Install with shim after adjusting input shaft.

186 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

5th gear synchromesh

1- Springs for locking pieces
2- Locking collar with 3 recesses -arrows A- for locking pieces
-4-
3- Synchro-hub
4- Locking pieces - Installation position: The thin extensions
-arrows B- face the pointed teeth of the locking collar -2-

Assembling 5th gear locking collar/synchro-hub

– Slide locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
direction. The recesses for the locking pieces in locking collar and
synchro-hub must be aligned ( ⇒ page 187 ).
– Fit locking pieces (installation position: ⇒ page 187 ).
– Insert springs offset by 120° underneath lug -C-. Angled ends
of spring must be in front of locking pieces -arrows-.

Installing offset springs -A-

This type of spring is fitted on both sides.
– The springs are only used together with hollow locking pieces
(with internal recess).
– Fit locking pieces (installation position: ⇒ page 187 ).

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Installation position of springs:
– Insert springs offset by 120°.
– Angled end -A- of spring must locate in hollow locking piece.
Spring must be fitted under lug -B- of locking pieces.
The offset end must always point away from synchro-hub (in di‐
rection of -arrow-).

1. Input shaft 187

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1.2 Adjusting input shaft

(Determining thickness of shim for input shaft)

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ End measuring plate -
VW 385/17-
♦ Thrust pad -VW 510-
♦ Thrust plate -VW 447 i-
♦ Press tool -VW 407-
♦ Torque wrench -V.A.G
1331-
♦ Dial gauge

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

The input shaft must be re-adjusted when the following compo‐

nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Input shaft
♦ 4th gear wheel
or
♦ Tapered roller bearings for input shaft
Table of adjustments ⇒ page 226
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.

188 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Press tapered roller bearing outer race onto stop in clutch

housing.

– Press tapered roller bearing outer race by

Protected without
copyright.shim onto
Copying stopor commercial purposes, in part or in whole, is not
for private
in gearbox housing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install input shaft in clutch housing and put on gearbox hous‐
ing. Tighten hexagon bolts to 25 Nm.

– Fit measuring appliance and dial gauge in clutch housing.

– Before measurement, rotate input shaft to allow tapered roller
bearings to settle. Preload dial gauge to 1 mm and set to „0“.

Note

This procedure must be repeated for each subsequent measure‐

ment, as otherwise the dial gauge will not return to its original
setting.

1. Input shaft 189

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Push input shaft towards dial gauge in direction of -arrow-.

– Read off and note play indicated on dial gauge (in this exam‐
ple: 1.21 mm).

Note

Dial gauge does not return to original setting by itself.

Determine thickness of shim.

Example:
Bearing clearance (measured Thickness of shim according to
value) table
1.21 mm 1.175 mm

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

190 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Table of shims
Bearing clearance Shim
Measured value (mm) Thickness (mm)
0.671 … 0.699 0.650
0.700 … 0.724 0.675
0.725 … 0.749 0.700
0.750 … 0.774 0.725
0.775 … 0.799 0.750
0.800 … 0.824 0.775
0.825 … 0.849 0.800
0.850 … 0.874 0.825
0.875 … 0.899 0.850
0.900 … 0.924 0.875
0.925 … 0.949 0.900
0.950 … 0.974 0.925
0.975 … 0.999 0.950
1.000 … 1.024 0.975
1.025 … 1.049 1.000
1.050 … 1.074 1.025
1.075 … 1.099 1.050
1.100 … 1.124 1.075
1.125 … 1.149 1.100
1.150 … 1.174 1.125
1.175 … 1.199 1.150
1.200 … 1.224 1.175
1.225 … 1.249 1.200
1.250 … 1.274 1.225
1.275 … 1.229 1.250
1.300 … 1.324 1.275
1.325 … 1.349 1.300
1.350 … 1.374 1.325
1.375 … 1.399 1.350
1.400 … 1.424 1.375
1.425 … 1.449 1.400
1.450 … 1.474 1.425
1.475 … 1.499 1.450
1.500 … 1.524 1.475
1.525 … by
Protected 1.549 1.500
copyright. Copying for private or commercial purposes, in part or in whole, is not
1.550 … 1.574 1.525
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.575 … 1.599 1.550
1.600 … 1.624 1.575
1.625 … 1.649 1.600
1.650 … 1.674 1.625
1.675 … 1.699 1.650
1.700 … 1.724 1.675

Note

Select correct shims from ⇒ Electronic parts catalogue .

– Remove input shaft and press tapered roller bearing outer

race out of gearbox housing using thrust plate -VW 447 i- .
– Insert shim of correct thickness.
If the size of the shim required is larger than those listed in the
table, install two shims amounting to the correct value. Install the
thicker of the two shims first.

1. Input shaft 191

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Press tapered roller bearing outer race together with the cor‐
rect shim (1.175 mm in example) into gearbox housing using
thrust pad -VW 510- .
– Assemble gearbox housing and tighten hexagon bolts to 25
Nm and then turn 90° further.

Checking adjustment
– Install measuring appliance and dial gauge.
– Rotate input shaft to allow tapered roller bearings to settle.
– Press input shaft in direction of -arrow-.
– Bearing clearance should be min. 0.01 ... max. 0.09 mm.

Note

If the bearing clearance cannot be measured, but input shaft play

is perceptible and the input shaft turns freely, the adjustment is
acceptable.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

192 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

2 Output shaft
⇒ „2.1 Exploded view - dismantling and assembling output shaft“,
page 193
⇒ „2.2 Adjusting output shaft“, page 206

2.1 Exploded view - dismantling and assembling output shaft

Special tools and workshop

equipment required
♦ Press tool -VW 407-
♦ Press tool -VW 412-
♦ Thrust pad -VW 512-
♦ Puller -V.A.G 1582-
♦ Adapter -V.A.G 1582/4-
♦ Adapter -V.A.G 1582/5-
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Output shaft 193

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Thrust plate -VW 402-

♦ Thrust piece -32 - 111-
♦ Press tool -VW 408 A-
♦ Press tool -VW 409-
♦ Support rails -VW 457-
♦ Tube -VW 519-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

194 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Thrust ring -VW 429-

♦ Tube -VW 415 A-
♦ Thrust plate -VW 447 H-
♦ Press tool -VW 454-
♦ Installing sleeve -VW 455-
♦ Drift sleeve -41-501-

♦ -1- Internal puller -Kukko 21/6-

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ -3- Splitter -Kukko 17/2-

♦ -4- Counter-support -Kukko 22/2-

2. Output shaft 195

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Inductive heater -VAS 6414-

♦ Feeler gauge

Note

♦ The output shaft is dismantled as follows:- Position splitter under 2nd speed selector gear
( ⇒ Item 21 (page 198) ) and press off as described in ⇒ page 200 . Remove circlip
⇒ Item 17 (page 198) . Then press off locking collar and synchro-hub for 1st and 2nd gear as shown in
⇒ page 200 .
♦ Refer to general repair instructions ⇒ page 5 .
♦ Refer to ⇒ Electronic parts catalogue and technical data ⇒ page 1 when installing new gears or a new output
shaft.
♦ Always renew both tapered roller bearings together.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

196 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Nut
❑ 25 Nm + 90°
❑ 4 nuts for bearing
mounting
2 - Clutch housing
3 - Shim
❑ For output shaft
❑ Table of adjustments
⇒ page 226
4 - Small tapered roller bearing
outer race
❑ Removing ⇒ page 199
❑ Pressing in
⇒ page 199
5 - Small tapered roller bearing
inner race
❑ Pulling off ⇒ page 200
❑ Pressing on
⇒ page 200
6 - Output shaft
❑ Adjusting ⇒ page 206
7 - Large tapered roller bearing
inner race
❑ Pulling off ⇒ page 201
❑ Pressing on
⇒ page 201
8 - Seal
❑ Place seals (4x) on bolts
for bearing mounting
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Bearing mounting permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ With large tapered roller bearing outer with
race and bolts
respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Only renew outer race together with large tapered roller bearing and bearing mounting
10 - Thrust washer
❑ Shoulder on thrust washer faces towards tapered roller bearing
11 - 1st speed selector gear
12 - Needle bearing
❑ For 1st gear
13 - Synchro-ring
❑ (Inner ring for 1st gear)
❑ Installation position ⇒ page 201
❑ Checking for wear ⇒ page 201
❑ Check lugs for scoring
14 - Outer ring for 1st gear
❑ Installation position ⇒ page 201
❑ Checking for wear ⇒ page 202
❑ Renew if scored or if there are visible traces of wear
15 - 1st gear synchro-ring
❑ Installation position ⇒ page 201
❑ Checking for wear ⇒ page 202

2. Output shaft 197

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

16 - Locking collar with synchro-hub for 1st and 2nd gear

❑ Press off together with bearing mounting ⇒ Item 17 (page 198) after removing circlip ⇒ page 200
❑ Dismantling ⇒ page 202
❑ Assembling locking collar/synchro-hub ⇒ page 202 , ⇒ page 202 and ⇒ page 203
❑ Installation position ⇒ page 203
❑ Pressing on ⇒ page 203
17 - Circlip
18 - 2nd gear synchro-ring
❑ Checking for wear ⇒ page 202
❑ Assemble so that the recesses engage on the locking pieces on the locking collar
⇒ Item 16 (page 198)
19 - Outer ring for 2nd gear
❑ Insert in synchro-ring ⇒ Item 18 (page 198)
❑ Installation position ⇒ page 203
❑ Renew if scored or if there are visible traces of wear
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Checking for wear ⇒ page 202
❑ Check lugs for scoring
❑ Installation position ⇒ page 204
21 - 2nd speed selector gear
❑ Installation position ⇒ page 204
22 - Needle bearing
❑ For 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with 2nd speed selector gear ⇒ page 200
❑ Pressing on ⇒ page 204 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
25 - Needle bearing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For 3rd gear
26 - 3rd speed selector gear
27 - 3rd gear synchro-ring
❑ Checking for wear ⇒ page 204
28 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Pressing off with 2nd speed selector gear ⇒ Item 21 (page 198) and 3rd speed selector gear
⇒ Item 26 (page 198) ⇒ page 200
❑ Dismantling ⇒ page 205
❑ Assembling locking collar/synchro-hub ⇒ page 205 , ⇒ page 205 and ⇒ page 205
❑ Installation position: Locking collar/synchro-hub ⇒ page 205
❑ Pressing on ⇒ page 206
29 - Sleeve
❑ For 4th gear needle bearing
❑ Pressing off with locking collar and synchro-hub for 3rd and 4th gear ⇒ Item 28 (page 198)
⇒ page 200
❑ Pressing on ⇒ page 206
30 - Needle bearing
❑ For 4th gear

198 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

31 - 4th gear synchro-ring

❑ Checking for wear ⇒ page 204
32 - 4th speed selector gear
33 - Thrust washer
34 - Needle bearing
❑ For output shaft
❑ Removing and installing ⇒ page 166
35 - Gearbox housing
36 - Sleeve
❑ For needle bearing/output shaft
❑ Pressing off ⇒ page 200
❑ Pressing on ⇒ page 206
37 - 5th gear wheel
❑ Pulling off individually ⇒ page 141
❑ Pulling off together with gearbox housing ⇒ page 147
38 - Dished spring
❑ Installation position ⇒ page 160
39 - Bolt
❑ Tightening torque ⇒ Item 4 (page 137)
❑ Always renew
❑ Removing and installing ⇒ page 147

Pulling out small tapered roller bearing outer race

A - Internal puller 37 ... 46 mm , e.g. -Kukko 21/6-
B - Counter-support , e.g. -Kukko 22/2-

Pressing in small tapered roller bearing outer race

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Output shaft 199

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pulling off small tapered roller bearing inner race

A - Soft jaws/vice
– Fit adapter and apply tension to it behind the bearing rollers,
then turn bearing and re-tension adapter.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub/locking collar; 2nd, 3rd
and 4th speed selector gears with needle bearing sleeve for out‐
put shaft
A - Splitter 22...115 mm , e.g. -Kukko 17/2-
B - Hexagon bolt (M10 x 20), 17 mm

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Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing mounting

– First remove circlip -arrow-.

200 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pulling off large tapered roller bearing inner race

-A- - Jaw covers
– Before fitting puller, insert M10 x 20 hexagon bolt in hole in
output shaft.

Pressing on large tapered roller bearing inner race

-A- Thrust washer
– Fit thrust washer before pressing on inner race. Shoulder
faces towards tapered roller
Protected bearing
by copyright. inner
Copying race.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation position of inner ring, outer ring and synchro-ring for

1st gear
– Place inner ring -A- on 1st speed selector gear.
The angled tabs -arrow 1- point towards the outer ring -B-.
– Fit outer ring -B-.
The tabs -arrow 2- lock in the recesses -arrow 3- of the selector
gear.
– Fit synchro-ring -C-.
The recesses -arrow 4- locate on the tabs -arrow 1- of the inner
ring -A-.

Note

If components are not being renewed, make sure they are re-
installed on the same gear.

Checking inner ring for 1st and 2nd gear for wear
– Press inner ring onto tapered seat on selector gear and meas‐
ure gap -a- using a feeler gauge.
Gap -a- Installation depth Wear limit
1st and 2nd gear 0.75 ... 1.25 mm 0.3 mm

2. Output shaft 201

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Checking 1st and 2nd gear synchro-ring for wear

– Press synchro-ring, outer ring and inner ring onto tapered seat
on selector gear and measure gap -a- using a feeler gauge.
Gap -a- Installation depth Wear limit
1st and 2nd gear 1.2 ... 1.8 mm 0.5 mm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Dismantling and assembling 1st and 2nd gear locking collar and
synchro-hub
1 - Spring
Select correct spring from ⇒ Electronic parts catalogue .
Assembling version used together with hollow locking pieces
⇒ page 202
Assembling version used together with solid locking pieces
⇒ page 203
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
Select locking pieces from ⇒ Electronic parts catalogue .
Shoulders on synchro-hub are of equal width on both sides.
The shoulder on one side is chamfered -arrow B-.
When assembled, the chamfer on the shoulder of the synchro-
hub and the external teeth on the locking collar -arrow A- face in
the same direction.
The recesses for the locking pieces on synchro-hub and locking
collar -arrow C- must align.

Assembling locking collar/synchro-hub for 1st and 2nd gear (ver‐

sion with hollow locking pieces)
• Locking collar is pushed over synchro-hub.
– Insert locking pieces and install springs offset at 120°. Angled
end of spring must locate in hollow locking piece.

202 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Assembling locking collar/synchro-hub for 1st and 2nd gear (ver‐

sion with solid locking pieces: no internal recess)
• Locking collar is pushed over synchro-hub.
– Insert locking pieces and install springs offset at 120°. Angled
ends of spring must be in front of locking pieces -arrows-.

Installation position of 1st and 2nd gear locking collar/synchro-

hub
Splines on locking collar -arrow- point to splines for 3rd/4th gear
synchro-hub -A-.

Heat 1st and 2nd gear locking collar/synchro-hub and press on

WARNING

Wear protective gloves.

Turn synchro-ring so that grooves align with locking pieces.

Installation position of outer ring for 2nd gear

The lugs -arrows- face towards 1st gear -A-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Output shaft 203

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installation position of synchro-ring (inner ring for 2nd gear) -A-

The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-
ring -B-.

Installation position of 2nd speed selector gear

The higher shoulder -A- faces towards 1st gear -B-. The recesses
in the shoulder -arrows- engage on the lugs on the outer ring
⇒ page 203 .

Pressing on sleeve for 3rd gear needle bearing

Checking 3rd and 4th gear synchro-ring for wear

– Press synchro-ring onto tapered seat on selector gear and
measure gap -a- with a feeler gauge.
Gap -a- Installation depth Wear limit
3rd gear 1.0 … 1.7 mm 0.5 mm
4th gear 1.0 … 1.7 mm
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

204 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Select correct spring from ⇒ Electronic parts catalogue .
Assembling version used together with hollow locking pieces
(with internal recess) ⇒ page 205
Assembling version used together with solid locking pieces (no
internal recess) ⇒ page 205
2 - Locking piece
Select locking pieces from ⇒ Electronic parts catalogue .
3 - Locking collar
4 - Synchro-hub
– Slide locking collar over synchro-hub.
Recesses for locking pieces in synchro-hub and locking collar
must align.

Assembling locking collar/synchro-hub for 3rd and 4th gear (ver‐

sion with hollow locking pieces)
Locking collar is pushed over synchro-hub.
– Insert locking pieces and install springs offset at 120°. Angled
end of spring must locate in hollow locking piece.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Assembling locking collar/synchro-hub for 3rd and 4th gear (ver‐

sion with solid locking pieces: no internal recess)
• Locking collar is pushed over synchro-hub.
– Insert locking pieces and install springs offset at 120°. Angled
ends of spring must be in front of locking pieces -arrows-.

Installation position of 3rd and 4th gear locking collar/synchro-hub

Chamfer -arrow- faces towards 4th gear.

2. Output shaft 205

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Heat and press on 3rd and 4th gear synchro-hub with locking col‐
lar

WARNING

Wear protective gloves.

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for needle bearing/output shaft

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 Adjusting output shaft

(Determining thickness of output shaft shim)

206 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ End measuring plate -
VW 385/17-
♦ Thrust pad -VW 512-
♦ Straightening tool -3114/2-
♦ Press tool -VW 407-
♦ Torque wrench -
V.A.G 1331-
♦ Dial gauge

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ -1- Internal puller -Kukko 21/6-

♦ -4- Counter-support -Kukko 22/2-

The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Output shaft (final drive gear set)
♦ Clutch housing
or
♦ Tapered roller bearings for output shaft

2. Output shaft 207

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Table of adjustments ⇒ page 226

Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
– Press small tapered roller bearing outer race together with
0.65 mm shim onto stop in clutch housing ⇒ page 199 .
– Insert output shaft and tighten bearing mounting nuts to 25 Nm
and then turn 90° further.
– Turn output shaft approx. 20 to 30 turns in one direction.

Note

♦ The output shaft has to be turned in one direction to seat the

rollers in the tapered roller bearing.
♦ This requires 20 to 30 turns.
♦ If this is neglected, the measurement will not be correct.

– Mount dial gauge (3 mm measuring range) and set to „0“ with

1 mm preload. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Move output shaft up andwith
down;
respect read off and ofnote
to the correctness playinindi‐
information this document. Copyright by AUDI AG.
cated on dial gauge (in this example 0.20 mm).
Determining thickness of shim
The specified bearing preload is obtained by adding a constant
preload figure (0.10 … 0.15 mm) to the thickness of the shim in‐
stalled (0.65 mm) and the measured value obtained (0.20 mm).
Example:
Bearing clearance = Thickness of shim according to
shim (0.65 mm) + measured table
value
0.850 mm 1.000 mm

208 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove output shaft and pull out small tapered roller bearing
outer race ⇒ page 199 .
Table of shims
Bearing clearance = Thickness
shim (0.65 mm) of shim (mm)
+ measured value
0.650 0.750
0.660 … 0.689 0.800
0.690 … 0.739 0.850
Protected0.740 … 0.789
by copyright. 0.900
Copying for private or commercial purposes, in part or in whole, is not
0.790 … 0.839 0.950
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
0.840 … 0.889 1.000
0.890 … 0.939 1.050
0.940 … 0.989 1.100
0.990 … 1.039 1.150
1.040 … 1.089 1.200
1.090 … 1.139 1.250
1.140 … 1.189 1.300
1.190 … 1.239 1.350
1.240 … 1.289 1.400
1.290 … 1.339 1.450
1.340 … 1.389 1.500
1.390 … 1.429 1.550

Note

♦ Select correct shims from ⇒ Electronic parts catalogue .

♦ Tolerance variations make it possible to obtain the exact shim
thickness required.

– Insert shim of correct thickness.

If the size of the shim required is larger than those listed in the
table, install two shims amounting to the correct value. Install the
thicker of the two shims first.
• If the original shim (0.65 mm) is to be refitted, check the shim
for damage.

– Press in small tapered roller bearing outer race together with

the correct shim (in example 1.00 mm).
– Install output shaft, tighten nuts for bearing mounting in clutch
housing to 25 Nm and then turn 90° further.

2. Output shaft 209

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3 Exploded view - dismantling and assembling reverse shaft

Special tools and workshop

equipment required
♦ Press tool -VW 454-
♦ Thrust plate -VW 447 H-
♦ Press tool -VW 411-
♦ Centring mandrel -12 - 551-
♦ Thrust plate -VW 401-
♦ Press tool -VW 408 A-

♦ -1- Internal puller -Kukko 21/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ -4- Counter-support -Kukko 22/1-

210 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Note

After removal, always renew needle bearings in clutch housing and in reverse shaft support.

1 - Clutch housing
2 - Needle bearing
❑ Pulling out ⇒ page 211
❑ Pressing in
⇒ page 212
3 - Reverse gear wheel
4 - Circlip
❑ Always renew
Protected afterCopying
by copyright. re‐ for private or commercial purposes, in part or in whole, is not
moving
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Reverse selector gear
❑ Remove circlip before
renewing
❑ Shoulder faces towards
reverse gear wheel
6 - Reverse shaft
❑ Removing and installing
⇒ page 147
7 - Needle bearing
❑ Pressing out
⇒ page 212
❑ Pressing in
⇒ page 212
8 - Reverse shaft support
❑ Removing and installing
⇒ page 147

Pulling needle bearing out of clutch housing

A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 14.5 ... 18.5 mm , e.g. -Kukko 21/2-

Note

The needle bearing is destroyed during removal and must be re‐

newed.

3. Exploded view - dismantling and assembling reverse shaft 211

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing needle bearing -A- into clutch housing

Pressing needle bearing out of reverse shaft support

Pressing needle bearing into reverse shaft support

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

212 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

39 – Final drive - front differential

1 Renewing oil seals for flange shafts
with gearbox installed in vehicle
♦ ⇒ „1.1 Renewing oil seal for flange shaft (left-side)“,
page 213
♦ ⇒ „1.2 Identification of flange shaft oil seals (right-side)“, page
215
♦ ⇒ „1.3 Renewing flange shaft oil seal (right-side) - two-piece
oil seal and sleeve“, page 216
♦ ⇒ „1.4 Renewing oil seal together with sleeve (one-piece
sleeve and oil seal for flange shaft (right-side))“, page 221

1.1 Renewing oil seal for flange shaft (left-side)

Special tools and workshop

equipment required
♦ Multi-purpose tool -
VW 771-
♦ Puller hook -VW 771/37-
♦ Thrust piece -T10160-
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
♦ Torque wrench -
V.A.G 1331-
♦ Sealing grease -G 052 128
A1-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
• Gearbox in vehicle
– Remove left wheel.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 213
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Remove noise insulation (centre) by releasing fasteners

-1 ... 3-.

– Remove front section of wheel housing liner (left-side)

-fasteners 1 ... 3-.
– Turn steering to the left.
– Unbolt drive shaft from flange shaft ⇒ Running gear, front-
wheel drive and four-wheel drive; Rep. gr. 40 .
– Lift drive shaft clear and tie in place. Do not damage surface
coating.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.

– Remove securing bolt for flange shaft (left-side); to do so,

screw two bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.

– Pull out flange shaft oil seal using multi-purpose tool -VW 771-
and puller hook -VW 771/37- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

214 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing
– Lightly oil outer circumference of new oil seal.
– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease -G 052 128 A1- .

– Drive in new oil seal onto stop (take care to keep oil seal
straight).
– Install flange shaft.
– Press flange shaft in against spring on gearbox housing and
secure with countersunk bolt. Tightening torque
⇒ Item 12 (page 230)
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 132 .

– Install front section of wheel housing liner (left-side)

-fasteners 1 ... 3-.
– Install noise insulation under engine/gearbox ⇒ General body
repairs, exterior; Rep. gr. 50 .
– Fit front left wheel ⇒ Rep. gr. 44 .

1.2 Identification of flange shaft oil seals

(right-side)
The flange shaft oil seal -1- (right-side) is always fitted inside a
sleeve -2-.
There are two different versions: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Two-piece oil seal and sleeve permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ One-piece oil seal and sleeve

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 215
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Two-piece oil seal -1- and sleeve -2-.

• Identification: recesses on sleeve -arrow- all around.
Renewing oil seal ⇒ page 216

One-piece oil seal -1- and sleeve -2-.

• Identification: without recesses or annular groove -arrow- on
sleeve.
Oil seal and sleeve can only be renewed together ⇒ page 221 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.3 Renewing flange shaft oil seal (right-

side) - two-piece oil seal and sleeve
• ⇒ „1.2 Identification of flange shaft oil seals (right-side)“, page
215
Special tools and workshop equipment required
♦ Assembly tool -3253/2-

♦ Engine support -3300 A-

216 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Support -T10036-

♦ Thrust piece -T10160-

♦ Used oil collection and extraction unit -V.A.G 1782-

Removing
– Remove noise insulation (centre) by releasing fasteners
-1 ... 3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 217
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– If fitted, unbolt heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shaft (right-side) from flange shaft ⇒ Running
gear, front-wheel drive and four-wheel drive; Rep. gr. 40 .

– Remove bolts
Protected -1 ... 3-
by copyright. andfordetach
Copying private orpendulum support.
commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unbolt heat shield for power steering control unit -J500- from
subframe -arrows-.

– Drill two 7 mm diameter holes in support -T10036- , as illus‐

trated (if holes have not already been drilled).
• Dimension -a- = 11 mm
• Dimension -b- = 98 mm
• Dimension -c- = 70 mm

218 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Bolt support -T10036- onto subframe -arrows- using two

M6 × 20 bolts.

– Bolt engine support -3300 A- onto support -T10036- .

– Move drive shaft clear towards the rear as far as possible.
– Using spindle of engine support , push engine forwards just
far enough to give a small amount of clearance between flange
shaft and drive shaft -arrow-. Pay special attention to the fol‐
lowing points:
• Alternator should only make light contact with refrigerant pipe.
• Air conditioner compressor should only make light contact with
refrigerant pipe connection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Place used oil collection and extraction unit -V.A.G 1782-

respectun‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with to the correctness of information in this document. Copyright by AUDI AG.
derneath.

– Remove securing bolt -arrow- for flange shaft. To do this,

screw two bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.

– Lever out oil seal using a screwdriver -A- (support screwdriver

on assembly tool -3253/2- ).

Note

♦ Do not damage sleeve, otherwise leaks will occur.

♦ Renew sleeve if damaged ⇒ page 167

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 219
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing
– Lightly oil outer circumference of new oil seal.
– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease -G 052 128 A1- .

– Drive in new oil seal onto stop (take care to keep oil seal
straight).

– Install flange shaft.

– Press flange shaft in against spring on gearbox housing and
secure with countersunk bolt -arrow-. Tightening torque
⇒ Item 12 (page 230)
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Detach engine support -3300 A- and support -T10036- .

– Install and secure heat shield for power steering control unit
on subframe -arrows-.
– If originally fitted, bolt on heat shield for drive shaft (right-side).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

220 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Fit pendulum support with new bolts -1 … 3- in accordance

with installation instructions ⇒ page 127 . Tightening torques
⇒ page 122
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 132 .
– Install noise insulation under engine/gearbox ⇒ General body
repairs, exterior; Rep. gr. 50 .
Tightening torque
Component Nm
Heat shield for drive shaft to cylinder block, M10 25
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

1.4 Renewing oil seal together with sleeve

with respect to the correctness of information in this document. Copyright by AUDI AG.

(one-piece sleeve and oil seal for flange

shaft (right-side))
• ⇒ „1.2 Identification of flange shaft oil seals (right-side)“, page
215

Special tools and workshop

equipment required
♦ Thrust piece -T10148-
♦ Spindle from assembly de‐
vice -3066-
♦ Multi-purpose tool -
VW 771-
♦ Puller hook -VW 771/37-
♦ Torque wrench -
V.A.G 1331-

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 221
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ Engine support -3300 A-

♦ Support -T10036-

Removing
– Remove noise insulation (centre) by releasing fasteners
-1 ... 3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

222 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– If fitted, unbolt heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shaft (right-side) from flange shaft ⇒ Running
gear, front-wheel drive and four-wheel drive; Rep. gr. 40 .

– Remove bolts -1 ... 3- and detach pendulum support.

– Unbolt heat shield for power steering control unit -J500- from
subframe -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Drill two 7 mm diameter holes in support -T10036- , as illus‐

trated (if holes have not already been drilled).
• Dimension -a- = 11 mm
• Dimension -b- = 98 mm.
• Dimension -c- = 70 mm.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 223
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Bolt support -T10036- onto subframe -arrows- using two

M6 × 20 bolts.

– Bolt engine support -3300 A- onto support -T10036- .

– Move drive shaft clear towards the rear as far as possible.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Using spindle of engine support , push engine forwards just
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

far enough to give a small amount of clearance between flange

with respect to the correctness of information in this document. Copyright by AUDI AG.

shaft and drive shaft -arrow-. Pay special attention to the fol‐
lowing points:
• Alternator should only make light contact with refrigerant pipe.
• Air conditioner compressor should only make light contact with
refrigerant pipe connection.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
derneath.

– Remove securing bolt -arrow- for flange shaft. To do this,

screw two bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.

– Pull out oil seal with sleeve.

A projection is located on inside diameter of sleeve.
– Position puller hook -VW 771/37- directly behind projection in
sleeve.
– During this operation, press puller hook -VW 771/37- firmly in
against sleeve.

224 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installing
– Clean seat for oil seal in gearbox.
– Pull in oil seal together with sleeve.
A - Spindle from assembly device -3066- screwed into threaded
piece in differential.
B - M12 nut
– Turn nut -B- and pull oil seal with sleeve in onto stop with thrust
piece -T10148- .
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .

– Install flange shaft.

– Press flange shaft in against spring on gearbox housing and
secure with countersunk bolt -arrow-. Tightening torque
⇒ Item 12 (page 230)
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Detach engine support -3300 A- and support -T10036- .

– Install and secure heat shield for power steering control unit
on subframe -arrows-.
– If originally fitted, bolt on heat shield for drive shaft (right-side).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit pendulum support with new bolts -1 … 3- in accordance

with installation instructions ⇒ page 127 . Tightening torques
⇒ page 122
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 132 .
– Install noise insulation under engine/gearbox ⇒ General body
repairs, exterior; Rep. gr. 50 .
Tightening torque
Component Nm
Heat shield for drive shaft to cylinder block, M10 40

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 225
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

2 Table of adjustments

Note

When performing repairs on the gearbox it is only necessary to

re-adjust the input shaft, output shaft or differential if components
have been renewed which have a direct effect on the adjustment
of the gearbox. Refer to the following table to avoid unnecessary
adjustment work:

Components requiring adjustment:

Input shaft Output shaft Differential
⇒ page 188 ⇒ page 206 ⇒ page 235
Components renewed: Gearbox housing x x
Clutch housing x x x
Input shaft x
Output shaft (final drive gear set) x
Differential cage x
Tapered roller bearings for input x
shaft
Tapered roller bearings for output x
shaft
Tapered roller bearings for differen‐ x
tial
4th gear wheel x

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

226 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

3 Differential
♦ ⇒ „3.1 Exploded view - dismantling and assembling differen‐
tial“, page 227
♦ ⇒ „3.2 Adjusting differential“, page 235

3.1 Exploded view - dismantling and assembling differential

Special tools and workshop

equipment required
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/3-
♦ Press tool -VW 412-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 227
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Press tool -VW 408 A-

♦ Press tool -VW 473-
♦ Thrust plate -30 - 205-
♦ Sleeve -3144-
♦ Press tool -2007-
♦ Torque wrench -V.A.G
1332-

♦ Press tool -40 - 21-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

228 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

♦ Thrust plate -40 - 105-

♦ -1- Internal puller -Kukko 21/7-

♦ -4- Counter-support -Kukko 22/2-

Note

♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Always renew both tapered roller bearings together.
♦ Adjust differential if tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed
⇒ page 235 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 229
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

1 - Gearbox housing
2 - Shim
❑ For differential
❑ Determining thickness
⇒ page 235
3 - Tapered roller bearing outer
race
❑ Pulling out ⇒ page 232
❑ Pressing in
⇒ page 233
4 - Tapered roller bearing inner
race
❑ Pulling off ⇒ page 232
❑ Pressing on
⇒ page 232
5 - Differential cage
❑ With final drive gear
❑ Differential cage is
matched to one-piece
thrust washer
⇒ page 234
❑ Hole for spring pin is
matched to length of
spring pin ⇒ page 233
❑ Allocate according to ⇒
Electronic parts cata‐
logue
6 - Tapered roller bearing inner
race
❑ Pulling off ⇒ page 232
❑ Pressing on
⇒ page 232
7 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 231
❑ Pressing in ⇒ page 232
8 - Clutch housing
9 - Sleeve
❑ For oil seal ⇒ Item 10 (page 230)
❑ Removing and installing ⇒ page 162
10 - Oil seal
❑ ⇒ „1.1 Renewing oil seal for flange shaft (left-side)“, page 213
❑ ⇒ „1.3 Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve“, page 216
11 - One-piece oil seal and sleeve
❑ If oil seal is damaged, renew both sleeve and oil seal ⇒ page 221
12 - Countersunk bolt
❑ 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Screws into with
threaded piece
respect to the ⇒ Item
correctness 20 (page
of information 231)
in this document. Copyright by AUDI AG.

13 - Flange shaft
❑ Removing and installing ⇒ page 213
14 - Spring for flange shaft
❑ Installed behind flange shafts

230 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

15 - Thrust washer
❑ Installation position ⇒ page 235
16 - Tapered ring
❑ With grooves to engage on thrust washer
❑ Installation position: Taper towards differential cage
17 - Circlip
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - One-piece thrust washer
❑ Lubricate with gear oil before installing
❑ One-piece thrust washer has a projection on some versions ⇒ page 234
19 - Sun wheel
❑ Installing ⇒ page 234
20 - Threaded piece
❑ Installing ⇒ page 234
21 - Differential pinion pin
❑ Removing in conjunction with short spring pin ⇒ page 233
❑ Removing in conjunction with long spring pin ⇒ page 234
❑ Installing ⇒ page 234
22 - Spring pin
❑ Secures differential pinion pin
❑ Spring pins of two different lengths are fitted
❑ Identification of different types of spring pin ⇒ page 233
❑ Short spring pin: removing and installing ⇒ page 233
❑ Long spring pin: is sheared off on removal ⇒ page 234
❑ Long spring pin: installing ⇒ page 234
23 - Planet pinion
❑ Installing ⇒ page 234
24 - Sun wheel
❑ Installing ⇒ page 234

Pressing tapered roller bearing outer race out of clutch housing

– First remove mounting sleeve for flange shaft oil seal.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 231
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing tapered roller bearing outer race into clutch housing

No shim is installed on the clutch housing side.

Pulling off tapered roller bearing inner races

– Before setting up the puller, place thrust plate -40 - 105- on
differential cage.

Note

The procedure for pulling the tapered roller bearing inner races
off the differential cage is the same for both bearings.

Pressing on tapered roller bearing inner races

Note

The same special tools are used for pressing on tapered roller
bearing inner races for gearbox housing and clutch housing.

Pulling tapered roller bearing outer race out of gearbox housing

A - Counter-support , e.g. -Kukko 22/2-
B - Internal puller 46 ... 58 mm , e.g. -Kukko 21/7-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

232 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Pressing tapered roller bearing outer race into gearbox housing

– Fit shim below outer race.
– Support gearbox housing with sleeve -3144- directly below
bearing mounting.

Identification of different types of spring pin

Dimension „a“ (mm) Identification
28.5 (short spring pin), Annular groove -arrows-
removing and installing ⇒ page 233
36.0 (long spring pin), No annular groove
removing ⇒ page 234 ,
installing ⇒ page 234

Identification of differential cage

– Check drilling for spring pin in differential cage.
The drilling in the differential cage has been modified to accom‐
modate the longer spring pin.
Hole Length of spring pin (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Spring pin with annular groove (short spring pin): removing and
installing
Removing
– Cover up tapered roller bearing inner race and speedometer
drive wheel to keep out metal particles and to prevent damage.
– Drive out spring pin with chisel, inserting chisel into annular
groove.
Installing
– Drive fully into differential cage.

3. Differential 233
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Removing spring pin without annular groove (long spring pin):

press out differential pinion pin
The spring pin is sheared off when pressing out.
– Drive the remaining part of the spring pin out of the differential
cage.

Installing spring pin without annular groove (long spring pin)

– Align drilling in differential pinion pin with drilling in differential
cage.
– Use a punch -1- to drive in new spring pin to dimension -a- =
3.0 mm.
• The spring pin must not come into contact with the gearbox
when the differential cage is installed.

On some versions the one-piece thrust washer hasbyacopyright.

Protected projection
Copying for private or commercial purposes, in part or in whole, is not
next to the holes -A-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

In this case the differential cage has a corresponding annular slot

-B-.
– Lubricate one-piece thrust washer with gear oil and install.
– Position one-piece thrust washer so it engages in slot -B- in
differential cage.

Installing differential bevel gears and differential pinion pin

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Fit planet pinions (180° apart) and pivot into position.
– Push differential pinion pin -arrow A- in as far as first planet
pinion.
– Fit threaded pieces -arrows B- in sun wheels.
Installation position: Stepped shoulder towards sun wheel
– Drive differential pinion pin into final position and secure with
spring pin.

234 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

Installation position of thrust washer for tapered ring -1-

Collar -arrow- faces spring -B-.
Some gearbox versions have projections -A-.
The projections -A- face towards tapered ring -1-.

3.2 Adjusting differential

Special tools and workshop

equipment required
♦ End measuring plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Press tool -VW 407-
♦ Thrust plate -30 - 205-
♦ Torque wrench -
V.A.G 1331-
♦ -1- Internal puller -Kukko
21/7-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ -4- Counter-support -Kukko
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
22/2- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Dial gauge

3. Differential 235
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

The differential has to be readjusted when the following compo‐

nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or
♦ Tapered roller bearings for differential
Table of adjustments ⇒ page 226
– Press tapered roller bearing outer race without shim into gear‐
box housing using thrust plate -30 - 205- ⇒ page 233 .

Note

The tapered roller bearing inner and outer races are paired. Do
not interchange.

– Press tapered roller bearing outer race into clutch housing

⇒ page 232 using thrust plate -30 - 205- .
– Install differential in clutch housing.
– Place gearbox housing in position and tighten 5 bolts to 25
Nm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

236 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
5-speed manual gearbox 0A4 - Edition 02.2011

– Attach dial gauge and set to „0“ with a preload of 1 mm.

– Move differential up and down and read off and note play in‐
dicated on dial gauge. (0.70 mm in this example.)
Determining thickness of shim
The specified bearing preload is obtained by adding a constant
preload figure (0.25 mm) to the reading indicated (0.70 mm).
Example:
Bearing clearance (measured Thickness of shim according to
value) table
0.70 mm 0.95 mm
Table of shims
Bearing clearance Shim
Measured value Thickness
(mm) (mm)
0.303 … 0.449 0.650
0.450 … 0.499 0.700
0.500 … 0.549 0.750
0.550 … 0.599 0.800
0.600 … 0.649 0.850
0.650 … 0.699 0.900
0.700 … 0.749 0.950
0.750 … 0.799 1.000
0.800 … 0.849 1.050
0.850 … 0.899 1.100
0.900 … 0.949 1.150
0.950 … 0.999 1.200
1.000 … 1.049 1.250
1.050 … 1.099 1.300
1.100 … 1.149 1.350
1.150 … 1.199 1.400

Note

♦ Select correct shims from ⇒ Electronic parts catalogue .

♦ Tolerance variations make it possible to obtain the exact shim
thickness required.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Detach gearbox housing and pull tapered roller bearing outer
race out of gearbox housing.
A - Counter-support , e.g. -Kukko 22/2-
B - Internal puller 46 ... 58 mm , e.g. -Kukko 21/7-
– Insert shim of correct thickness.
If the size of the shim required is larger than those listed in the
table, install two shims amounting to the correct value. Install the
thicker of the two shims first.
– Press in outer race of differential tapered roller bearing again
and secure gearbox housing ⇒ page 233 .

3. Differential 237