Service

Workshop Manual
Audi A3 2004 ➤
Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S
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 A0050306920

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Calculating ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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 - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 13
2.1 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 13
3 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Exploded view - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Removing and installing pipe/hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5 Exploded view - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8 Overview - servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Clutch identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2 Exploded view - Sachs version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3 Removing and installing clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Exploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Exploded view - gear knob and gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3 Separating gear lever boot from gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.4 Exploded view - gear lever and selector housing on vehicles up to model year 2008 . . . . 61
1.5 Exploded view - selector mechanism on vehicles from model year 2008 onwards . . . . . . 64
1.6 Dismantling and assembling selector mechanism on vehicles from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.8 Exploded view - gear selector cable and gate selector cable up to model year 2007 . . . . 76
1.9 Exploded view - gear selector cable and gate selector cable from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 85
1.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine . . . . . . . . . . . . . . . . 90
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine . . . . . . . . . . . . . . . . 109
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Contents i
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.3 Removing and installing gearbox bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5 Checking gear oil level and filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.2 Draining off gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.3 Filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2 Exploded view - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.3 Exploded view - removing and installing gearbox housing cover and 5th/6th gear . . . . . . 142
6.4 Exploded view - removing and installing gearbox housing and selector mechanism . . . . . . 145
6.5 Exploded view - removing and installing input shaft, output shaft, differential and selector
forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.6 Assembly sequence - removing and installing gearbox housing cover and 5th/6th gear . . 148
6.7 Assembly sequence - dismantling and assembling complete gearbox . . . . . . . . . . . . . . . . 154
7 Exploded view - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.1 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
8 Exploded view - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.1 Servicing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
9 Exploded view - servicing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.1 Dismantling and assembling selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
10 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.1 Exploded view - selector forks in conjunction with reverse selector gear arrow . . . . . . . . 187
10.2 Exploded view - selector forks in conjunction with locking collar for reverse gear arrow . . 189
10.3 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.1 Exploded view - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.1 Exploded view - reverse shaft with reverse selector gear arrow . . . . . . . . . . . . . . . . . . . . 227
3.2 Exploded view - reverse shaft with locking collar for reverse gear arrow . . . . . . . . . . . . . . 228
3.3 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1 Renewing oil seals for flange shafts with gearbox installed in vehicle . . . . . . . . . . . . . . . . 233
1.1 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.2 Identification of flange shaft oil seals (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.3 Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve . . . . . . . . . . . . 236
1.4 Renewing oil seal together with sleeve (one-piece sleeve and flange shaft oil seal (right-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
side)) . . . . . . . . . . . . .permitted
. . . . .unless
. . . .authorised
. . . . . by
. .AUDI
. . . AG.
. . AUDI
. . . .AG. .does
. . not
. . guarantee
. . . . . .or. accept
. . . .any
. . liability
......... 239
2 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
244
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.1 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

ii Contents
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

3.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

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.

Contents iii
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

iv Contents
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

00 – Technical data
1 Gearbox identification
• ⇒ „1.1 Code letters, allocation, transmission ratios, capaci‐
ties“, page 1
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ -Arrow 2- manual gearbox 02S

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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.

Manual gearbox 02S -arrow 2-

Code letters and date of manufacture of gearbox

Example: GLB 18 07 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
♦ Allocation of clutch type

1. Gearbox identification 1
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Manual gearbox 6-speed 02S

Code letters FNC GLB GQP
Manufactured from 02.03 02.03 08.03
to 03.03 08.03 05.04
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Engine 2.0 ltr. - 110 kW FSI 2.0 ltr. - 110 kW FSI 2.0 ltr. - 110 kW FSI
Ratio Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox 2.1 ltr.
(gearbox completely dismantled)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Capacity of manual gearbox permitted unless authorised by1.9 ltr.AG. AUDI AG does not guarantee or accept any liability
AUDI
⇒ page 137 (gearbox partially with respect to the correctness of information in this document. Copyright by AUDI AG.
dismantled)

Manual gearbox 6-speed 02S

Code letters HXP JCN JWX
Manufactured from 10.06 06.06 01.07
to 11.06 08.06 05.08
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008
►
Engine 1.8 ltr. - 118 kW FSI tur‐ 2.0 ltr. - 110 kW FSI 1.8 ltr. - 118 kW FSI tur‐
bo bo
Ratio Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox 2.1 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.9 ltr.
⇒ page 137 (gearbox partially
dismantled)

Manual gearbox 6-speed 02S

Code letters JXR KVT MDP
Manufactured from 08.06 05.08 11.09
to 06.08 11.09 06.10
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008 Audi A3 Cabriolet 2008
► ►
Engine 2.0 ltr. - 110 kW FSI 1.8 ltr. - 118 kW FSI tur‐ 1.8 ltr. - 118 kW FSI tur‐
bo bo
Ratio Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox 2.1 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.9 ltr.
⇒ page 137 (gearbox partially
dismantled)

Manual gearbox 6-speed 02S

Code letters MUE MUF NMY

2 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Manual gearbox 6-speed 02S

Manufactured from 11.10 06.10 11.10
to 11.10
Allocation Model Audi A3 2004 ► Audi A3 2004 ► Audi A3 2004 ►
Audi A3 Cabriolet 2008 Audi A3 Cabriolet 2008 Audi A3 Cabriolet 2008
► ► ►
Engine 1.8 ltr. - 118 kW FSI tur‐ 1.8 ltr. - 118 kW FSI tur‐ 1.8 ltr. - 118 kW FSI tur‐
bo bo bo
Ratio Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox 2.1 ltr.
(gearbox completely dismantled)
Capacity of manual gearbox 1.9 ltr.
⇒ page 137 (gearbox partially
dismantled)

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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.

1. Gearbox identification 3
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

2 Transmission layout

Note

Arrows point in direction of travel.

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Output shaft
6 - Differential
I - 1st gear
II - 2nd 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
III - 3rd gear with respect to the correctness of information in this document. Copyright by AUDI AG.

IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

4 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3 Calculating ratio „i“

Example:
6th gear Final drive
Drive gear ZG1 = 38 ZA1 = 17
Driven gear ZG2 = 31 ZA2 = 62

i = Z2 : Z1 1)
iG = gear ratio = ZG2 : ZG1 = 31 : 38 = 0.816
iA = axle ratio = ZA2 : ZA1 = 62 : 17 = 3.647
iov = overall ratio

iov = iG x iA = 0.816 x 3.647 = 2.975

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

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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. Calculating ratio „i“ 5

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
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Manual ⇒ Workshop equipment and permitted
specialunless
tools .
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
♦ 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 allocation of bolts and other components, refer 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.
♦ 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 137
2.1 ltr. 1.9 ltr.
Sealants
♦ Thoroughly clean housing contact surfaces before applying
sealing paste .
♦ Apply sealing paste -AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste .

6 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
Protected tolerances).
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
♦ Lightly lubricate O-rings with oil before
with respect toinstallation
the correctness to preventin this document. Copyright by AUDI AG.
of information
them being trapped during assembly.
♦ Check oil level after installing new gaskets, O-rings and oil
seals ⇒ page 137 .

Locking elements

♦ 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-.

4. General repair instructions 7

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

cured with locking fluid. Then apply locking fluid -

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.
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, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
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

8 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
♦ Clean before pressing on.
♦ 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 6th speed selector gears for min‐
imal 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.

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.

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

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

4. General repair instructions 9

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Abnormal wear on locking collar:

C - Worn chamfer on internal splines of locking collar.

♦ In comparison: intact locking collar:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
D - Intact chamfer permitted
on internal splinesbyofAUDI
unless authorised locking collar.
AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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
and slave cylinder“, page 13 ).
♦ 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.

10 Rep. gr.00 - Technical data

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

5. Safety precautions for vehicles with start/stop system 11

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 13 and perform
⇒ „2.1 Function check for clutch master cylinder and slave cylinder“, page 13 prior to renewing.

I-
⇒ „3 Exploded view - pedal
cluster, clutch master cylin‐
der“, page 15
⇒ „3.1 Removing and installing
over-centre spring“, page 16

⇒ „3.2 Removing and installing

clutch pedal“, page 18

⇒ „3.3 Removing and installing

mounting bracket“, page 21

⇒ „3.4 Removing and installing

clutch position sender G476 “,
page 24

⇒ „3.5 Removing and installing

clutch master cylinder“,
page 26

II -
⇒ „4 Exploded view - hydraul‐
ics (LHD)“, page 29
⇒ „4.1 Removing and installing
clutch slave cylinder“,
page 31

⇒ „6 Bleeding clutch system“,

page 40

III -
⇒ „5 Exploded view - hydraul‐
ics (RHD)“, page 38

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 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 13 .
♦ 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.
♦ The vent opening must be uncovered, otherwise the perma‐
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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Check the complete hydraulic system for permitted
leaks. 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 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).

2. Notes on removing and installing clutch master cylinder and slave cylinder 13
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 40 .
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 40 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.

14 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3 Exploded view - pedal cluster, clutch master cylinder

1 - Pipe/hose assembly
❑ With frequency modula‐
tor
❑ Disconnecting from
clutch master cylinder
and slave cylinder
⇒ page 31
❑ Removing and installing
⇒ page 36
2 - Seal or O-ring
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 30
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
3 - Clip
4 - Supply hose
❑ To brake fluid reservoir
❑ Made of rubber or plas‐
tic, depending on ver‐
sion
❑ Plastic supply hose with
additional seals
⇒ page 30
5 - Nut
❑ 20 Nm
❑ 3x
❑ Self-locking
❑ Renew
6 - Seal
❑ Renew
7 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing ⇒ page 21
8 - Bolt
9 - Bearing bush
10 - Pivot pin
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - permitted
Clutchunless
pedal authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ withRemoving and installing ⇒ page 18
respect to the correctness of information in this document. Copyright by AUDI AG.

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

12 - Bearing bush
13 - Nut
❑ 25 Nm
❑ Self-locking
❑ Renew
14 - Retaining clip
❑ For operating rod on clutch master cylinder
15 - Over-centre spring
❑ Removing and installing ⇒ page 16
16 - Seal
❑ Renew
17 - Clutch master cylinder
❑ Removing and installing ⇒ page 26
18 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 24
❑ Can be checked in „Guided fault finding“ using ⇒ vehicle diagnostic tester

Crash bar - tightening torque

– 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
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Special tools and workshop equipment required
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Assembly tool -T10178-

16 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Grease -G 000 450 02-

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.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
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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.

– 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.

Installing
• Tightening torque ⇒ page 15
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- .

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.
– Install crash bar ⇒ page 16 .
– 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-

♦ Grease -G 000 450 02-

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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.

18 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unbolt crash bar -2- (secured by one or two bolts -arrows
permitted unless B-,
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
depending on version). with respect to the correctness of information in this document. Copyright by AUDI AG.

– 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.

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

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

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Installing
• Tightening torque ⇒ page 15
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- .

– 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.

– Install crash bar ⇒ page 16 .

– Install footwell vent (front left) ⇒ Heating, air conditioning;
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Rep. gr. 80 . 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 storage compartment on driver's side ⇒ General body
repairs, interior; Rep. gr. 68 .

20 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3.3 Removing and installing mounting

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

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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.

♦ Hose clip pliers -VAS 6340-

Removing
Vehicles with 2.0 ltr. FSI engine:
– Disconnect hose -1- and connector -2- at air cleaner housing.
– Remove bolt -3-.
– Release spring clips -4- and detach air intake hose.
– Take out air cleaner housing.

Vehicles with 1.8 ltr. TFSI engine:

– Pull off cover for air duct (release retaining clips -arrows- on
the sides).

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Pull off bottom section of air duct (release retaining clips

-arrows-).
– Detach bottom section of air duct with air hose.

– Unplug electrical connector -1- from air mass meter -G70- .

– Remove air hose -2-.
– Remove bolt -4- and remove air cleaner housing.

Note

-Item 3- can be disregarded.

All vehicles:
– Move driver's seat to rear as far as possible and move steering
wheel into uppermost position.

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

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

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– With ignition switched off, disconnect

with respectbattery earth ofstrap
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness information in this document. Copyright by AUDI AG.
-arrow-.

22 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

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

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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

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.

– Use hose clamp -3094- to 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 clip -2- with a screwdriver and disconnect pipe/hose
assembly -1- from clutch master cylinder.
– Unclip and detach clutch position sender -G476- from clutch
master cylinder -arrow-. Electrical connector -4- can remain
connected.

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.
– 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-.
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Installing 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 ⇒ page 15
Installation is carried out in reverse sequence; note the following:

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-.

– Connect pipe/hose assembly ⇒ page 31 .
– Bleed clutch system ⇒ page 40 .
– Install crash bar ⇒ page 16 .
– 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. 24 .

3.4 Removing and installing clutch position

sender -G476-
Removing
– Remove air cleaner housing completely ⇒ Rep. gr. 24 .

24 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

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

– With ignition switched off, disconnect battery earth strap

-arrow-.

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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 battery ⇒ Electrical system; Rep. gr. 27 .

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

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

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

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
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 .
– Install air cleaner housing ⇒ Rep. gr. 24 .

3.5 Removing and installing clutch master

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

26 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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 13 .
♦ When working in the footwell, put cloths on the floor covering
to protect it from possible brake fluid spills.

– Remove mounting bracket ⇒ page 21 .

– Release retaining clip for operating rod on clutch master cyl‐
inder using pliers -T10005- .

– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
♦ 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-.

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

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 27

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
♦ Length of spacer = approx. 40 mm (e.g. 1/2" socket).

– 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 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.

28 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 30
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 26
5 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
6 - Retaining clip
❑ For operating rod on
clutch master cylinder
❑ To remove and install
retaining clip first detach
clutch master cylinder
from clutch pedal
⇒ page 18
7 - Clutch pedal
❑ Removing and installing
⇒ page 18
8 - Nut
❑ For securing mounting
bracket to plenum
chamber partition panel
❑ Tightening torque ⇒ Item 5 (page 15)
❑ Always renew
9 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 30
❑ 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 (vibration damper) on some versions
❑ For correct version, refer to Protected
⇒ Electronic parts
by copyright. catalogue
Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ page 36
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.
❑ Disconnecting from clutch master cylinder and clutch slave cylinder ⇒ page 31
11 - Bracket
❑ For pipe/hose assembly ⇒ Item 10 (page 29)
❑ Secured on body

4. Exploded view - hydraulics (LHD) 29

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

12 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 30
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ 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 31
15 - Bolt
❑ 20 Nm
❑ 2x
16 - Bleeder screw
❑ 6 Nm
❑ Bleeding clutch system ⇒ page 40
17 - Dust cap
18 - Gearbox
19 - Bracket
❑ For pipe/hose assembly
20 - Bolt
❑ 20 Nm

Vehicles with plastic supply hose -1-

• Seals -2- must be fitted in supply hose.

Seal/O-ring for pipe/hose assembly

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

30 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 30 .
♦ 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-

Removing

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ If you suspect a permitted
defective clutch slave cylinder, perform func‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

tion test prior to renewing

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“, page 13 .
♦ 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.

– Remove air cleaner housing completely ⇒ Rep. gr. 24 .

Caution

Follow steps required when disconnecting battery ⇒ Electrical

system; Rep. gr. 27 .

4. Exploded view - hydraulics (LHD) 31

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– With ignition switched off, disconnect battery earth strap

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

– Remove battery tray -arrows-.

Vehicles with metal gate 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 gate
relay lever -B-.
– Pull both cables off pins.
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.

Arrows -3 … 4- can be disregarded.

32 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Vehicles with plastic gate 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 70 .
– Press detent -arrow 2- down onto stop and remove gate relay
lever together with cable end-piece. Move gate relay lever in
normal direction of operation.

Note

-Arrow 3- can be disregarded.

Vehicles with plastic gate relay lever with clip -arrow 1-

– Pull out clip -arrow 1- and remove gate relay lever together
with cable end-piece -arrow 2-.

Continued for by
Protected allcopyright.
vehicles: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
– Detach cable
with respectsupport bracket
to the correctness from gearbox
of information -arrows-.
in this document. Copyright by AUDI AG.

– Tie back gear selector cable and gate selector cable.

4. Exploded view - hydraulics (LHD) 33

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Then detach gearbox support -arrows A-.

– Remove clutch slave cylinder -arrows B-.

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 master 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
Protected 31 . 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
– Lubricate
with respect toend of plunger
the correctness with grease
of information for clutch
in this document. plate
Copyright splines
by AUDI AG. -
G 000 100- .
– Install clutch slave cylinder and tighten bolts -1- and -2-. Tight‐
ening torque ⇒ Item 15 (page 30)
– Clip pipe/hose assembly into bracket -arrow-.
– Remove hose clamp -3094- .

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

ques ⇒ Item 1 (page 127)
– Bleed clutch system ⇒ page 40 .

34 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

Metal gate relay lever -B-:

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

Note

Arrows -3 … 4- can be disregarded.

Plastic gate relay lever with detent -arrow 1-:

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

Plastic gate relay lever with clip -arrow 1-

– Fit gate relay lever and secure with clip -arrow 1-.
Continued for all vehicles:
– Adjust selector mechanism ⇒ page 86 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 24 .
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 ➤
6-speed manual gearbox 02S - Edition 02.2011

4.2 Removing and installing pipe/hose as‐

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

Removing
– Remove air cleaner housing completely ⇒ Rep. gr. 24 .

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 .

– 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.

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.

36 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

master cylinder.

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

assembly -1- from clutch master cylinder and clutch slave cyl‐
inder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Detach pipe/hose assembly -1- from with

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

Caution

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

sembly.

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

Note

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

⇒ page 30 .
♦ 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 into bracket -arrow-.

– Remove hose clamp -3094- .
– Bleed clutch system ⇒ page 40 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 24 .

4. Exploded view - hydraulics (LHD) 37

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 38)
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 26
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
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 30
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
7 - Retaining clip
❑ To remove and install retaining clip first detach clutch
Protected master
by copyright. cylinder
Copying from
for private clutch pedal
or commercial ⇒inpage
purposes, 18
part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
8 - Clutch pedal with respect to the correctness of information in this document. Copyright by AUDI AG.

9 - Nut
❑ 20 Nm
❑ For securing mounting bracket to plenum chamber partition panel
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 30

38 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
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
❑ Push onto pipe connection
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Lubricate with brake fluid before installing

❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 30
❑ 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 ⇒ page 31
19 - Bolt
❑ Tightening torque ⇒ Item 15 (page 30)
20 - Bleeder screw
❑ Tightening torque ⇒ Item 16 (page 30)
❑ Bleeding clutch system ⇒ page 40
21 - Dust cap
22 - Gearbox
23 - Bracket
24 - Bolt
❑ ⇒ Item 20 (page 30)

5. Exploded view - hydraulics (RHD) 39

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 .

Vehicles with 1.8 ltr. TFSI engine:

– Remove air cleaner housing completely ⇒ Rep. gr. 24 .
Continued for all vehicles:
– Pull clutch pedal back to its normal rest position.
– 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.

40 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Connect bleed hose to bleeder connection -arrow-.

– Now switch on bleeding equipment.
♦ Operating pressure 2.0 bar
– Open bleeder screw.
– Bleed off about 100 cm3 of brake fluid.
– Close bleeder screw.
– Rapidly pump clutch pedal through full range of travel 10 to 15
times.
– Open bleeder screw once again.
– Bleed off an additional 50 cm3 of brake fluid.
– Tighten bleeder screw 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.
Vehicles with 1.8 ltr. TFSI engine:
– Install complete air cleaner housing ⇒ Rep. gr. 24 .

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 41

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
❑ Renewing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 12 (page 175) 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 - Guide sleeve
❑ With vulcanised O-ring
and oil seal for input
shaft
⇒ Item 3 (page 42)
❑ 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-
5 - Retaining spring
❑ Secure to clutch release
lever
6 - Socket head bolt
❑ 20 Nm
7 - Clutch release lever
❑ Removing and installing
together with release bearing ⇒ page 43
❑ 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 43
❑ Lubricate surface which contacts release lever with grease for clutch plate splines -G 000 100-
9 - Bolt
❑ Tightening torque ⇒ Item 15 (page 30)
❑ 2x
10 - Clutch slave cylinder
❑ Removing and installing ⇒ page 31
11 - Plunger
❑ Lubricate end of plunger with grease for clutch plate splines -G 000 100-
12 - Assembly bolt
❑ Secures the clutch release lever while installing gearbox

42 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ 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
– Unhook spring -arrow 1-.
– Pull off clutch release lever -arrow 2- and clutch release bear‐
ing.
Perform installation in reverse sequence of removal.
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 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.

7. Exploded view - clutch release mechanism 43

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 51
♦ ⇒ „8.5 Removing and installing clutch (LuK version)“,
page 53

8.1 Clutch identification

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:
– Loosen fasteners -1 … 4- and remove noise insulation panel
(centre).

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.

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.

44 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

A - round contour -arrows- = Sachs version clutch

Exploded view - Sachs version clutch ⇒ page 45
B - square contour -arrows 1- and annular groove -arrow 2- = LuK
version clutch
or

B - round contour -arrows 1- and annular groove -arrow 2- = LuK

version clutch
Exploded view - LuK version clutch ⇒ page 51

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.

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. Overview - servicing clutch 45

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
⇒ page 50
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
3 - Pressure plate
❑ With adjustment mech‐
anism 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
❑ Identification with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 47
❑ Removing and installing
⇒ page 47
❑ Checking ends of dia‐
phragm spring
⇒ page 50
❑ Checking spring con‐
nections and rivets
⇒ page 50
❑ 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 bolts consecutively in steps of 90°

46 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Identification of self-adjusting Sachs version clutch

♦ Pressure plate with stop mechanism (position sensor)
-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

Instructions for removing dual-mass flywheel

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

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 removing the bolts, make sure that none of the bolt
heads contacts the dual-mass flywheel, as this would damage
the flywheel when the bolts are unscrewed further.

8.3 Removing and installing clutch (Sachs

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

8. Overview - servicing clutch 47

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

48 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Removing
– Remove gearbox
⇒ „2 Removing and installing gearbox on vehicles with 1.8 ltr.
TFSI engine“, page 90 or
⇒ „3 Removing and installing gearbox on vehicles with 2.0 ltr.
FSI engine“, page 109 .
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:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Apply counter-hold tool -3067- in order to loosen bolts.
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.
– 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
Installation is carried out in reverse sequence; note the following:

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.
♦ Always renew clutch plate and pressure plate together and
select the correct parts according to engine code ⇒ Electronic
parts catalogue .
♦ 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.
♦ 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).

8. Overview - servicing clutch 49

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Installation position of clutch plate

• Marking „Getriebeseite“ (gearbox side) and the protruding
spring cage face towards gearbox.

Checking ends of diaphragm spring

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

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-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Use counterhold tool -3067- . 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 pressure plate onto centring pins.
– Use centring mandrel -3190 A- to centralise clutch plate.

50 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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)
– Install gearbox ⇒ page 100 or ⇒ page 118 .

8.4 Exploded view - LuK 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.

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. Overview - servicing clutch 51

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 53
2 - Clutch plate
❑ Removing and installing
⇒ page 53
❑ Always renew SAC
pressure plate as well
❑ Installation position:
marking
„Getriebeseite“ (gear‐
box side) faces towards
gearbox
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For correct
permittedversion, re‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
fer to ⇒with
Electronic
respect to theparts
correctness of information in this document. Copyright by AUDI AG.
catalogue
3 - SAC pressure plate
❑ „SAC“ = self-adjusting
clutch
❑ Always renew clutch
plate as well
❑ Removing and installing
⇒ page 53
❑ Checking position of ad‐
juster ring on new SAC
pressure plate
⇒ page 55
❑ Only fits on flywheel in one position
❑ Checking ends of diaphragm spring ⇒ page 55
❑ Checking spring connection and rivets ⇒ page 55
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ 6x
❑ Loosen and tighten bolts consecutively in steps of 90°

52 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-

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.

♦ Grease for clutch plate splines -G 000 100-

8. Overview - servicing clutch 53

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Removing
– Remove gearbox
⇒ „2 Removing and installing gearbox on vehicles with 1.8 ltr.
TFSI engine“, page 90 or
⇒ „3 Removing and installing gearbox on vehicles with 2.0 ltr.
FSI engine“, page 109 .
– 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
Installation is carried out in reverse sequence; note the following:

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.
♦ Always renew clutch plate and pressure plate together and
select the correct parts according to engine code ⇒ Electronic
parts catalogue .
♦ Checking position of adjuster ring on new pressure plate
⇒ page 55
♦ 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 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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Pressure plates have an anti-corrosion coating
permitted unless and
authorised are AG. AUDI AG does not guarantee or accept any liability
by AUDI
greased. Only the contact surfacewithmay betocleaned,
respect otherwise
the correctness of information in this document. Copyright by AUDI AG.
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.
♦ 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).

54 Rep. gr.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Checking ends of diaphragm spring

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

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
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 position of adjustment mechanism (new SAC 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.

Installation position of clutch plate:

• The marking „Getriebeseite“ (gearbox side) faces towards the
gearbox

8. Overview - servicing clutch 55

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Use counterhold tool -3067- .

– Position pressure plate on centring pins.
– Use centring mandrel -3190 A- to centre 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 52)
– Install gearbox ⇒ page 100 or ⇒ page 118 .

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.30 - Clutch

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

34 – Controls, housing
1 Overview - selector mechanism
♦ ⇒ „1.1 Exploded view - gear knob and gear lever boot“,
page 59
♦ ⇒ „1.2 Removing and installing gear knob with gear lever
boot“, page 59
♦ ⇒ „1.3 Separating gear lever boot from gear knob“,
page 60
♦ ⇒ „1.4 Exploded view - gear lever and selector housing on ve‐
hicles up to model year 2008“, page 61
♦ ⇒ „1.5 Exploded view - selector mechanism on vehicles from
model year 2008 onwards“, page 64
♦ ⇒ „1.6 Dismantling and assembling selector mechanism on
vehicles from model year 2008 onwards“, page 65
♦ ⇒ „1.7 Removing and installing selector mechanism“,
page 69
♦ ⇒ „1.8 Exploded view - gear selector cable and gate selector
cable up to model year 2007“, page 76
♦ ⇒ „1.9 Exploded view - gear selector cable and gate selector
cable from model year 2008 onwards“, page 80
♦ ⇒ „1.10 Removing and installing gear selector cable and gate
selector cable“, page 85
♦ ⇒ „1.11 Adjusting selector mechanism“, page 86
-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 57

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 - Gate 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.

58 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 59
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Gear lever boot 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 and install to‐
gether with gear knob
⇒ page 59
6 - Cover for centre console
❑ Remove and install to‐
gether with gear knob
and gear lever boot
⇒ page 59
7 - Connecting piece
❑ Connects gear lever
boot and gear knob
❑ Different versions ⇒
Electronic parts cata‐
logue
8 - Clip
❑ 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 required
♦ Hose clip pliers -V.A.G 1275-

1. Overview - selector mechanism 59

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 59 .

60 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Unclip frame of gear lever boot from centre console cover

-arrows-.

– Cut through the connecting piece with a sharp knife at the point
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 59 .

1.4 Exploded view - gear lever and selector housing on vehicles up to model
year 2008

Note

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

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 ➤
6-speed manual gearbox 02S - 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 85 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
❑ Adjusting ⇒ page 86 with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Gear selector cable

❑ Removing and installing
⇒ page 85
❑ Adjusting ⇒ page 86
8 - Securing clip
❑ Renew
9 - Guide
❑ For spring
⇒ Item 26 (page 63)
10 - Ball socket with damper
11 - Cover
12 - Bush
13 - Securing clip
❑ Removing and installing ⇒ page 63
14 - Spring
15 - Bush
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

62 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

26 - Spring
❑ Installing ⇒ page 63
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 63

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 65)
4 - Damping washer
❑ Push onto gear lever as
far as stop -arrow-
5 - Securing clip
❑ Take care not to dam‐
age selector cables
when removing.
❑ Always renew
6 - Gate selector cable
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Installation position
⇒ page 57
7 - Bush
8 - Gear selector cable
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
❑ Lever off gear lever
with respect to the correctness of information in this document. Copyright by AUDI AG.
guide
❑ Press onto gear lever
guide inside selector mechanism
❑ Installation position ⇒ page 57
9 - Damper
10 - Ball socket
❑ Will be damaged during removal
❑ Always renew
11 - Bush
12 - Securing clip
❑ Removing and installing ⇒ page 63

64 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-

Dismantling
– Remove selector mechanism ⇒ page 69
– Using a screwdriver, bend open
Protected tabs Copying
by copyright. -arrows- on all
for private sides ofpurposes, in part or in whole, is not
or commercial
floor plate and removepermitted
floor plate.
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 gasket from selector housing.
– Remove gear selector cable and gate selector cable from se‐
lector housing ⇒ page 64 .

1. Overview - selector mechanism 65

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 steps, the bottom spring arm (-arrow 1-)
can become dislodged and snap downwards off the shoulder
of the gate selector lever.

– 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
Protected lever. 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
The with
spring arms
respect will thenofcompress
to the correctness „diagonally“.
information in this document. Copyright by AUDI AG.

66 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Theunless
permitted gearauthorised
lever guide rests
by AUDI AG. AUDIinAGthe larger
does recess
not guarantee -arrow-
or accept in the
any liability
thrust
with respectblock -T10083-
to the correctness .
of information in this document. Copyright by AUDI AG.

• The gear lever guide should protrude out of the selector hous‐
ing as far as the stop.

1. Overview - selector mechanism 67

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

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.

– Now insert gear lever guide (which is now fitted in selector

housing) into larger recess -arrow- in thrust block -T10083-
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-.

68 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 64 .
– Install selector mechanism ⇒ page 74 .

1.7 Removing and installing selector mech‐

anism 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
– Remove gear knob together with gear lever boot ⇒ page 59 .
– 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. 24 .

WARNING

Follow steps required when disconnecting battery ⇒ Rep. gr.

27 .

1. Overview - selector mechanism 69

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 gate relay lever -B-:
– Detach securing clip -arrow 2- for gate selector cable from gate
relay lever -B-.
– Pull gate selector cable and gear selector cable off joint pins.

Vehicles with plastic gate 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 gate relay lever forwards (in direction of
-arrow 3-).
• Do not detach cable end-piece from gate relay lever until gate
relay lever has been removed ⇒ page 84 .

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 ➤
6-speed manual gearbox 02S - Edition 02.2011

Continued for all vehicles:

– Detach cable support bracket 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.

Vehicles with 2.0 ltr. FSI engine:

– Remove covers on vehicle underside -arrows- (left and right).

– Unbolt support bracket for exhaust system -arrows-.

– Remove front tunnel cross-piece on vehicle underside

-arrows-.

1. Overview - selector mechanism 71

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Unclip all wiring at heat shield -arrows A-.

– Cut open cable tie -arrow B-.

– Remove rear tunnel cross-piece -1-.

– Take up weight of front section of exhaust system at catalytic
converter using engine/gearbox jack -V.A.G 1383 A- .

Note

To prevent damage, the flexible couplings in the front exhaust

pipe must not be bent further than 10°.

– Disconnect exhaust system at clamp -arrows-.

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Detach rear silencer -2- at rubber mountings and remove rear

section of exhaust system.
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
– Lower front section ofrespect
with exhaust system of
to the correctness slightly using
information in this engine
document. Copyright by AUDI AG.
and gearbox jack -V.A.G 1383 A- (not more than 10°). Make
sure there is sufficient clearance for Lambda probe wiring.

– Release clips -arrows- and pull out heat shield from the rear.

72 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Vehicles with 1.8 ltr. TFSI engine:

– Remove nuts -arrows- from covers on vehicle underside (left
and right).

– Pull inner side of cover on vehicle underside (right-side) down‐

wards slightly.
– Unplug electrical connector -arrow- on vehicle underside
(right-side).
– Take electrical connector out of bracket and move clear wiring
to Lambda probe -G39- .

– Remove front cross member on vehicle underside -arrows-.

Note

To prevent damage, the flexible couplings in the front exhaust

pipe must not be bent further than 10°.

– Loosen clamp -1- and move towards the rear.

– Unbolt support bracket for exhaust system -arrows-.

– Tie up front exhaust pipe on underbody.
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 73

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

– Release clips -arrows- and detach heat shield to rear.

All vehicles:
– Swing selector housing down and remove with selector ca‐
bles.

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:
• Tightening torques for vehicles up to model year 2008 -
⇒ page 61 or from model year 2008 onwards ⇒ page 64 .
– Install selector mechanism and tighten nuts -arrows-.

74 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 80 or ⇒ page 80
♦ 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 77 and ⇒ page 82

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

Continued for all vehicles:

– Attach cable support bracket to gearbox -arrows-.
– Adjust selector mechanism ⇒ page 86 .
– Install noise insulation covers above selector mechanism.
– Install ashtray in front section of centre console ⇒ General
body repairs, interior; Rep. gr. 68 .
– Protected
Installbygear knob
copyright. together
Copying for privatewith boot ⇒purposes,
or commercial page 59 . or in whole, is not
in part

– Install exhaust systemof and ensurein this stress-free alignment ⇒

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness information document. Copyright by AUDI AG.
Engine, mechanics; Rep. gr. 26 .
– Secure both tunnel cross-pieces on vehicle underside ⇒ En‐
gine, mechanics; Rep. gr. 26 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 .
– Install complete air cleaner housing ⇒ Rep. gr. 24 .

1. Overview - selector mechanism 75

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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

❑ Installation position
⇒ page 57
❑ Removing and installing
⇒ page 85
❑ Adjusting ⇒ page 86
❑ Secure to gate selector
cable with cable tie
⇒ page 80
2 - Gate selector cable
❑ Installation position
⇒ page 57
❑ Removing and installing
⇒ page 85
❑ Adjusting ⇒ page 86
❑ Secure to gear selector
cable with cable tie
⇒ page 80
3 - Securing clips
❑ Not fitted on vehicles
from model year 2008
onwards ⇒ page 64
4 - Selector housing
5 - Retaining clips
❑ Take care not to dam‐
age selector cables
when removing.
❑ Renew
6 - Bolt
❑ 20 Nm
❑ 3x
❑ For cable support brack‐
et
7 - Cable support bracket
❑ Made of metal or plastic, depending on version
❑ For correct version, refer to ⇒ Electronic parts catalogue
8 - Grommet
❑ Mounting for cable support bracket on gearbox
9 - Bush
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Cable end-piece 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.
❑ Secures gate selector cable to gate relay lever
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different

76 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

⇒ Fig. “„A - Identification according to diameter of bore in cable end-piece““ , page 77 or

⇒ Fig. “„B - Identification according to height of cable end-piece““ , page 78
❑ Detaching from gate selector cable ⇒ page 79
11 - Cable end-piece
❑ Secures gear selector cable to gearbox selector lever
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different
⇒ Fig. “„A - Identification according to diameter of bore in cable end-piece““ , page 77 or
⇒ Fig. “„B - Identification according to height of cable end-piece““ , page 78
❑ Detaching from gear selector cable ⇒ page 79
12 - Securing clips
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 ⇒
thepage 79 of information in this document. Copyright by AUDI AG.
correctness

❑ Renew
13 - Securing clip
❑ Removing ⇒ page 78
❑ Renew
14 - Bearing bushes
15 - Gate relay lever
❑ Installation position ⇒ page 79
16 - Slide block
17 - Gearbox selector lever
❑ With damper weight
❑ Install so that gap in splines aligns with selector shaft ⇒ page 78
❑ After installing, adjust selector mechanism ⇒ page 86
❑ Installation position ⇒ page 79
18 - Nut
❑ 23 Nm
❑ Self-locking
❑ Always renew

A - Identification according to diameter of bore in cable end-piece

The holes in the cable end-pieces have different diameters.
Cable end-piece for: Dimension „a“
Gear selector cable to gearbox selector lever 10 mm
Gate selector cable to gate relay lever 8 mm

1. Overview - selector mechanism 77

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

B - Identification according to height of cable end-piece

Cable end-piece for: Dimension „a“
Gear selector cable to gearbox selector lever 20 mm
Gate selector cable to gate relay lever 18.5 mm

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.

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 securing clip from gate relay lever

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

78 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Installation position: gearbox selector lever/gate relay lever

1 - Gearbox selector lever
- With damper weight
2 - Gate 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-.

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 gate relay lever -2-. Then pull gate selector cable off pin
-arrow-.
Securing

Note

♦ Renew securing clips.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Apply a small quantity of grease -Gunless
permitted 000authorised
450 02-by to the
AUDI AG.pins
AUDI AG does not guarantee or accept any liability
-arrows-. with respect to the correctness of information in this document. Copyright by AUDI AG.

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

1. Overview - selector mechanism 79

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

1.9 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- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Selector mechanism cover
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 - Slide block
3 - Gate relay lever
❑ Made of plastic
❑ Different versions avail‐
able; for correct version
refer to ⇒ Electronic
parts catalogue
❑ Installation position
⇒ page 82
❑ Detaching and securing
gate relay lever (with de‐
tent) at selector mecha‐
nism cover ⇒ page 83
❑ Detaching and securing
gate relay lever (with
clip) at selector mecha‐
nism cover ⇒ page 84
4 - Cable end-piece
❑ Secures gate selector
cable to gate relay lever
❑ Allocation ⇒ page 82
❑ Detaching from gate se‐
lector cable
⇒ page 83
5 - Gearbox selector lever
❑ With damper weight
❑ Fitting ⇒ page 82
❑ Installation position
⇒ page 82
❑ After installing, adjust
selector mechanism
⇒ page 86
6 - Nut
❑ Self-locking

80 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ Renew
❑ 23 Nm
7 - Cable end-piece
❑ Secures gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 82
❑ Detaching from gear selector cable ⇒ page 83
8 - Securing clip
❑ Removing ⇒ page 83
❑ Renew
9 - Retaining clips
❑ Renew
10 - Gate selector cable
❑ Removing and installing ⇒ page 85
❑ Adjusting ⇒ page 86
❑ Secure to gear selector cable with cable tie ⇒ page 85
11 - Selector housing
12 - Retaining clips
❑ Renew
13 - Gear selector cable
❑ Detaching and securing at gearbox selector lever ⇒ page 83
❑ Removing and installing ⇒ page 85
❑ Adjusting ⇒ page 86
❑ Secure to gate selector cable with cable tie ⇒ page 85
14 - Cable support bracket
15 - Bolt
❑ 20 Nm
16 - Grommet
17 - Bush
18 - Oil seal
❑ ForCopying
Protected by copyright. selector shaft
for private or commercial purposes, in part or in whole, is not

❑to the
Renewing
correctness of⇒information
page 186
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect in this document. Copyright by AUDI AG.

19 - Clip
❑ For gate relay lever (only from 08.2008 onwards)

1. Overview - selector mechanism 81

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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 gate relay lever 10 mm

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.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation position:
permittedgearbox selector
unless authorised lever/gate
by AUDI AG. AUDI AGrelaydoes notlever
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Gearbox selector lever
- With damper weight
2 - Gate relay lever
- Locates in guide rail of gearbox selector lever via slide block
-arrow-.

82 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 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 gate relay lever (with detent) at gearbox

selector lever (selector mechanism cover)
Detaching
– Press detent -arrow 1- down onto stop and remove gate relay
lever together with cable end-piece. Move gate relay lever in
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
normal direction of operation. with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

-Arrow 2- can be disregarded.

Securing

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– Press cable end-piece onto gate relay lever ⇒ page 84 .

– Insert gate relay lever with cable end-piece as far as stop.
• Gate 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 83

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Detaching and securing gate relay lever (with clip) at gearbox se‐
lector lever (selector mechanism cover)
Detaching
– Remove clip -arrow 1- and take off gate relay lever together
with cable end-piece.
Securing

Note

Lubricate all bearings and moving surfaces with grease -G 000

450 02- .

– Insert gate 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 gate relay
lever
• Gate relay lever removed
– Apply plain slot screwdriver -A- between bush -B- and gate
relay lever.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Pressing cable permitted
end-piece for gate selector cable onto gate relay
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.
lever
• Gate relay lever removed
• Press on cable end-piece only at bush -arrow-.
• Cable end-piece must move freely on gate relay lever.
• Cable end-piece must be behind detent.
– Ensure that components engage securely.

84 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
Removing
– Remove selector mechanism ⇒ page 69
– Using a screwdriver, bend open tabs -arrows- for selector
mechanism on floor plate and remove floor plate.
– Remove gasket.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Take off securing clips -1 ... 4- and detach gear selector cable
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

and gate selector cable from selector housing.

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

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 85

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 74 .
– Adjust selector mechanism ⇒ page 86 .

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.

86 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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, move gear lever to the left into 1st/
2nd gear gate.
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.

– 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. 24 .

Release cable end-pieces for gate selector cable and gear se‐
lector cable as follows:
– 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 87

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

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
– Now turn locking sleeves on
with gear
respectselector cable
to the correctness and gate
of information se‐document. Copyright by AUDI AG.
in this
lector cable as far as they will go in the direction indicated
-arrow-.
The spring presses the locking sleeve back into the original po‐
sition.

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.

88 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Check gear lever setting as follows:

• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– 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 far as it will go to the left and release.
– At the same time observe selector shaft on gearbox (2nd me‐
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 86 .
– Fit gear lever boot.
– Install complete air cleaner housing ⇒ Rep. gr. 24 .

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 89

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

2 Removing and installing gearbox on

vehicles with 1.8 ltr. TFSI engine

2.1 Removing gearbox

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.

♦ Engine support -3300 A-

90 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Support -T10036-

♦ Grease for clutch plate splines -G 000 100-

♦ Bolt M6 x 20 (2x)
♦ Bolt M10 x 20
Procedure
– Remove engine cover panel -arrows-.
– Remove air cleaner housing completely ⇒ Rep. gr. 24 .
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
Caution
with respect to the correctness of information in this document. Copyright by AUDI AG.

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 .

– Remove bolts -arrows- and detach battery tray -1-.

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 91
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Detach cable support bracket from gearbox -arrows-.

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

Metal gate 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 gate relay lever -B- and
pull off gate selector cable.
– Pull off securing clip -arrow 3- and remove gate relay lever
-B-.

Plastic gate 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 70 .
– Press detent -arrow 2- down onto stop and remove gate relay
lever together with cable end-piece. Move gate relay lever in
normal direction of operation.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
From 08.2008 onwards the gate relay lever
permitted unlessis secured
authorised withAG.a AUDI
by AUDI clip AG does not guarantee or accept any liability
⇒ page 33 . with respect to the correctness of information in this document. Copyright by AUDI AG.

Continued for all vehicles:

– Tie cables with cable support bracket to one side.
– Remove nut -arrow 3- and detach gearbox selector lever -A-.

92 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Detach gearbox support -1-.

– Move clear pipe/hose assembly leading to clutch slave cylin‐
der.
– 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.

– Unplug electrical connector -1-.

– Disconnect B+ wire from starter solenoid -2-.
– Disconnect earth wire -3- and remove top bolt securing starter.
– Unplug electrical connector -4- at reversing light switch -F4- .

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

from above).

– Remove the two top bolts on radiator cowl -top 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.

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 93
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Assemble support bracket -10 - 222 A- and place onto wing

panel flange, as shown in illustration.
– Engage hook of spindle in engine lifting eye (left-side).
– Take up weight of engine/gearbox assembly with spindle; do
not lift.

Audi A3
– Loosen fasteners -1 and 2- and remove noise insulation panel
(centre).

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

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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 noise insulation frame -arrow- ⇒ General body re‐

pairs, exterior; Rep. gr. 50 .
Continued for all vehicles
– Remove front left wheel.

94 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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- .

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

– Remove bottom starter mounting bolt and take out starter.

– Slightly lift retaining clip -1- and loosen hose clip -2- to remove
air hose.
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 on vehicles with 1.8 ltr. TFSI engine 95
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Detach electrical connector -1-.

– Remove remaining bolts -bottom arrows- and take out radiator
cowl from below.

– Unbolt 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.

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

– Spay studs on turbocharger -arrows- with rust remover.

– Remove nuts -arrows- from threaded pins.
– Detach catalytic converter from turbocharger
Protected andforsecure
by copyright. Copying private orcat‐
commercial purposes, in part or in whole, is not
alytic converter to prevent it from falling to the ground.
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 prevent damage, the flexible couplings in the front exhaust

pipe must not be bent further than 10°.
♦ -Item 1- and -item 2- can be disregarded.

96 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

ing.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Adjust spindle of support bracket -10 - 222 A- to lower gearbox

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

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

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

– Unplug electrical connector -1- at oil level and oil temperature

sender -G266- .
– Unclip bracket -2- for electrical wiring leading to oil level and
oil temperature sender -G266- at subframe.

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 97
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– If fitted, 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.

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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 support -T10036- onto subframe -arrows- using two

M6 × 20 bolts.

– Bolt engine support -3300 A- onto support -T10036- .

98 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Press engine towards front of vehicle using spindle of engine

support -3300 A- . Pay special attention to the following points:
• The air conditioner compressor -2- must not contact refriger‐
ant line -1- -arrow-.
• Alternator must not make contact with refrigerant line.
• Pressure pipe must not make contact with radiator.
To remove gearbox 02S, 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 -3282/39- .

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

ment plate .
• The arrow symbol -B- on the adjustment plate points in the
direction of travel.

– Place engine and gearbox jack -V.A.G 1383 A- underneath

vehicle.
– Align gearbox support -3282- parallel with gearbox.
– Screw pin -3282/29- into gearbox.
– Insert remaining support elements in gearbox as illustrated.
– Support gearbox from underneath by raising engine and gear‐
box jack -V.A.G 1383 A- .

– Remove remaining engine/gearbox securing bolts -5 and 6-.

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 on vehicles with 1.8 ltr. TFSI engine 99
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Push the gearbox off the dowel sleeves and swing carefully
towards the subframe.

Then guide flange shaft (right-side) -1- past recess -arrow- in in‐
termediate plate.
– Incline gearbox via spindles of gearbox support -3282- .
• The differential must face upwards.
• Pivot gearbox downwards in area of 6th gear.

– Guide gearbox with differential past subframe -A- and swivel

out.
– When lowering the gearbox, change position of gearbox using
the spindles on gearbox support -3282- .

2.2 Installing gearbox

Installation is carried out in reverse sequence; note the following:
Please note the information in the table below - „Checking gear
oil level and filling up with gear oil“.
„Checking gear oil level and filling up with gear oil“
»No« »Yes« »Yes«
Gearbox Replace‐ X
ment unit
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
No oil es‐ X permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
caping with respect to the correctness of information in this document. Copyright by AUDI AG.

Was com‐ X
pletely dis‐ Before in‐
mantled stalling
⇒ Item 3
(page 174)
Oil capacity
⇒ page 1

100 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 137
housing
and
clutch
housing
were not
separa‐
ted)

Note

♦ The special tools required are listed in the procedure for

⇒ „2.1 Removing gearbox“, page 90 .
♦ 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).

– 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 platebysplines
Protected -G 000
copyright. Copying for100-
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 on vehicles with 1.8 ltr. TFSI engine 101
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Incline gearbox via spindles of gearbox support -3282- .

• The differential must face upwards.
• Pivot gearbox downwards in area of 6th gear.
– Then raise gearbox carefully.

– Guide gearbox with differential past subframe -A- and swivel

in direction of -arrow-.
– Make sure longitudinal member -B- is not in the way.

• Guide flange shaft (right-side) -1- past recess -arrow- in inter‐

mediate plate.
– Align gearbox with engine in installation position and install.
– Bolt gearbox onto engine. Tightening torques ⇒ page 108
– Detach gearbox jack with gearbox support -3282- from gear‐
box after bolting gearbox to engine.
– Remove engine support -3300 A- and support -T10036- .
– Install starter ⇒ Electrical system; Rep. gr. 27 .

– Secure gearbox bracket -A- to gearbox with new bolts

-arrows-. Tightening torque ⇒ Item 8 (page 127)
– Pull gearbox up to support arm of gearbox mounting with spin‐
dle on 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.

102 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 .

– Use new bolts -arrows- to secure gearbox mounting to gear‐

box bracket. Tightening torque ⇒ Item 12 (page 128)

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 mountings of engine/gearbox assembly for correct ad‐

justment ⇒ Engine, mechanics; Rep. gr. 10 .

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

with installation instructions ⇒ page 132 . Tightening torques
⇒ page 127

– Secure catalytic converter to turbocharger -arrows- ⇒ Engine,

mechanics; Rep. gr. 26 .

Note

-Item 1- and -item 2- 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.

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 103
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Install radiator cowl -arrows- and attach electrical connector

-1-.

– Install air intake hose. Make sure retaining clip -arrow- snaps
onto retaining lug -A-.
– Secure drive shafts to flange shafts on gearbox ⇒ Running
gear, front-wheel drive and four-wheel drive; Rep. gr. 40 .
– Secure heat shield for drive shaft (right-side) to engine.

– Install clutch slave cylinder -arrows-. Tightening torque

⇒ Item 15 (page 30)
– Install gearbox support -1-. Tightening torque
⇒ Item 1 (page 127)
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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.

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

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

104 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

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

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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.

Metal gate relay lever -B-:

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– Install gearbox selector lever -A- ⇒ page 78 .

– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 77) .
– Fit gate 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 gate relay lever and secure with
securing clip -arrow 2-.

Plastic gate relay lever:

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

Note

From 08.2008 onwards the gate relay lever is secured with a clip
⇒ page 33 .

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 105
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Continued for all vehicles:

– Secure cable support bracket -arrows-. Tightening torque
⇒ Item 6 (page 76)
– Fit bracket -B- to gearbox.
– Push pipe/hose assembly -A- into bracket -B- on gearbox.
– Adjust selector mechanism ⇒ page 86 .

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

Rep. gr. 27 .
– Install air cleaner housing ⇒ Rep. gr. 24 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr.unless
permitted 10 .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 front section of wheel housing liner (left-side) ⇒ General

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

106 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Audi A3
– Install noise insulation (centre) -1 and 2- ⇒ General body re‐
pairs, exterior; Rep. gr. 50 .

Audi A3 Cabriolet
– Install noise insulation frame -arrow- ⇒ 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.

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

exterior; Rep. gr. 50 .

2. Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine 107
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Tightening torques
Engine/gearbox attachment (1.8 ltr. TFSI engine)
Item Bolt Nm
1, 2 M12 x 65 80
3 1)2) M12 x 150 80
4 1)2) M12 x 165 80
5 M10 x 50 40
6 M12 x 85 80
A Dowelunlesssleeves forbycentralising
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised AUDI AG. AUDI AG does not guarantee or accept any liability
• 1) Bolt with stud M8.
with respect to the correctness of information in this document. Copyright by AUDI AG.

• 2) Also starter to gearbox

Component Nm
Clutch pipe bracket to gearbox 20
Bracket for electrical wiring at bottom starter bolt 23
Heat shield for drive shaft to cylinder block 25

108 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3 Removing and installing gearbox on

vehicles with 2.0 ltr. FSI engine

3.1 Removing gearbox

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.

♦ Press tool -T10148-

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 109
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ 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

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 .

– 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.

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

battery.

110 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Disconnect hose -1- and connector -2- at air cleaner housing.

– Remove bolt -3-.
– Release spring clips -4- and detach air intake hose.
– Take out air cleaner housing.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove battery tray -arrows-.

– Detach front of battery tray from air duct.

– 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.

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 on vehicles with 2.0 ltr. FSI engine 111
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Detach cable support bracket from gearbox -arrows-.

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

Metal gate 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 gate relay lever -B- and
pull off gate selector cable.
– Pull off securing clip -arrow 3- and remove gate relay lever
-B-.

Plastic gate relay lever

– Detach securing clip -arrow 1- and pull off gear selector cable.
– Detach gate selector cable from cable end-piece ⇒ page 70 .
– Press detent -arrow 2- down onto stop and remove gate relay
lever together with cable end-piece. Move gate relay lever in
normal direction of operation.

Note

From 08.2008 onwards the gate relay lever is secured with a clip
⇒ page 33 .

Continued for all vehicles:

– Tie cables with cable support bracket to one side.
– Remove nut -arrow 3- and detach gearbox selector lever -A-.

112 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Remove gearbox support -arrows A-.

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

WARNING

Do not depress clutch pedal after removing slave cylinder.

– Remove upper engine/gearbox securing bolts.

– Remove engine cover panel -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.

– Position support bracket -10 - 222 A- on wing mounting flanges

with adapters -10 - 222 A /3- . Spindles face to the front.
– Take up weight of engine evenly with both spindles; do not lift.
– Raise vehicle.
– Remove front left wheel.
– Turn steering to the left.

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

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 113
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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- .

– Remove nut -2- and detach bracket -1- from stud together with
electrical wiring.
– Remove bottom starter mounting bolt and take out starter.

– Unbolt heat shield forProtected

right-side drive Copying
by copyright. shaft for
-arrows-.
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
– Unbolt drive shafts (left with
andrespect
right) from
to the gearbox
correctness flangeinshafts.
of information this document. Copyright by AUDI AG.

– 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.

114 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Unbolt support bracket for exhaust system -arrows-.

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

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

mounting.

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

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

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 115
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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

– Remove bolts -A- and -B- and take out strut -1-.

– 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.

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.
– 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.

To remove gearbox „02S“, set up gearbox support -3282- with

adjustment 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 .

116 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

♦ Distance between gearbox and engine is slightly greater at the
front than at the back.

– Push gearbox forwards slightly and bring it into the position

shown.
– Lower gearbox out of vehicle. When removing gearbox, en‐
sure sufficient clearance between sleeve -1- and pressure
plate -arrow- to prevent damage.

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 on vehicles with 2.0 ltr. FSI engine 117
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Note

If you will be installing a new gearbox instead of the one removed,

re-install flange shaft and tighten countersunk bolt -arrow-. Tight‐
ening torque ⇒ Item 1 (page 145)

3.2 Installing gearbox

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.
Installation is carried out in reverse sequence; note the following:
Please note the information in the table below - „Checking gear
oil level and filling up with gear oil“.
„Checking gear oil level and filling up with gear oil“
»No« »Yes« »Yes«
Gearbox Replace‐ X
ment unit
No oil es‐ X
caping
Was com‐ X
pletely dis‐ Before in‐
mantled stalling
⇒ Item 3
(page 174)
Oil capacity
⇒ page 1
Was parti‐ X
ally dis‐ After instal‐
mantled ling
• (gear‐ ⇒
box page 137
housing
and
clutch
housing
were not
separa‐
ted)

118 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Note

♦ The special tools required are listed in the procedure for

⇒ „3.1 Removing gearbox“, page 109 .
♦ 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.

– 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- .
– Raise gearbox carefully and move to installation position using
gearbox support 3282.
– Place adjustment plate 3282/39 on gearbox support 3282.
(Adjustment plate can only be fitted in one position.)
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383 A- .

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 119
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Screw support elements -A- and pin -3282/29- (-C-) into ad‐
justment plate , as illustrated.

– 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.

– Remove bolt -arrow- and pull flange shaft out of gearbox to‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gether with spring. 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.

– 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.

– 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.

120 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Lift gearbox. When installing gearbox, ensure sufficient clear‐

ance between sleeve -1- and pressure plate -arrow- to prevent
damage.
– Bring gearbox into position.
– Install bottom engine/gearbox securing bolts. Tightening tor‐
ques ⇒ page 125
– Detach gearbox jack with gearbox support -3282- from gear‐
box after bolting gearbox to engine.

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

-arrow-. Tightening torque ⇒ Item 12 (page 246)
– Install starter ⇒ Electrical system; Rep. gr. 27 .

– Install strut -1- and tighten bolts -A- and -B- ⇒ Engine, me‐
chanics; Rep. gr. 26 .

– Secure gearbox bracket -A- to gearbox with new bolts

-arrows-. Tightening torque ⇒ Item 8 (page 127)
– Install top engine/gearbox securing bolts. Tightening torques
⇒ page 125
– Lift engine/gearbox assembly slightly via the spindles of sup‐
port bracket -10 - 222 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.

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 121
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 gearbox mounting using new bolts

-arrows-. Tightening torque ⇒ Item 12 (page 128)

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 mountings of engine/gearbox assembly for stress-free

adjustment and re-adjust if necessary ⇒ Engine, mechanics;
Rep. gr. 10 .

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

with installation instructions ⇒ page 132 . Tightening torques
⇒ page 127
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Install heat shield for right-side drive shaft.

– Secure exhaust system -arrows- and align so it is free of stress

⇒ Engine, mechanics; Rep. gr. 26 .

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.

122 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Install clutch slave cylinder -arrows-. Tightening torque

⇒ Item 15 (page 30)
– Install gearbox support -1-. Tightening torque
⇒ Item 1 (page 127)

– Connect earth strap -3- at upper engine/gearbox securing bolt.

– Plug in electrical connector -4- at reversing light switch -F4- .

Metal gate relay lever -B-:

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

with respect to Note

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

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– Install gearbox selector lever -A- ⇒ page 78 .

– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 77) .
– Fit gate 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 gate relay lever and secure with
securing clip -arrow 2-.

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 123
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Plastic gate relay lever:

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

Note

From 08.2008 onwards the gate relay lever is secured with a clip
⇒ page 33 .

Continued for all vehicles:

– Secure cable support bracket -arrows-. Tightening torque
⇒ Item 6 (page 76)
– Fit bracket -B- to gearbox.
– Push pipe/hose assembly -A- into bracket -B- on gearbox.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Adjust selector mechanism ⇒authorised
permitted unless page 86 . AG. AUDI AG does not guarantee or accept any liability
by AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.

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

Rep. gr. 27 .
– Install air cleaner housing ⇒ Rep. gr. 24 .
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .

124 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 .

– Install noise insulation (centre) -1 ... 3- ⇒ General body re‐

pairs, exterior; Rep. gr. 50 .

Tightening torques
– Engine/gearbox attachment (2.0 ltr. FSI engine):
Item Bolt Qty. Nm
1 M 12 x 65 1 80
2 M 12 xCopying
1) Protected by copyright. 65 for private or commercial
1 purposes, in80
part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3 1)2) Mto12
with respect the x 150 of information in1 this document. Copyright
correctness 80 by AUDI AG.
4 1)2) M 12 x 165 1 80
5 M 10 x 50 3 40
6 M 12 x 85 1 80
A Dowel sleeves for 2
centralising
• 1) Bolt with stud M8.
• 2) Also starter to gearbox.

Clutch pipe bracket to gearbox 20

Bracket for electrical wiring at bottom starter 23
bolt
Heat shield for drive shaft to gearbox 25

3.3 Transporting gearbox

Special tools and workshop equipment required

3. Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine 125
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Gearbox lifting tackle -3336-

♦ Workshop hoist -VAS 6100-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Bolt gearbox
permitted lifting tackle
unless authorised by AUDI-3336-
AG. AUDIto
AGclutch
does not housing.
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– 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).

126 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

4 Exploded view - assembly mountings

1 - Bolt
❑ 20 Nm + 90°
❑ Gearbox support to
gearbox and gearbox
bracket
❑ Tightening sequence
⇒ page 128
❑ 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 131
6 - Bolt
❑ 50 Nm + 90°
❑ Pendulum support to
gearbox
❑ Always renew
7 - Bolt
❑ 50 Nm + 90°
❑ Pendulum support to gearbox
❑ Always renew
8 - Bolt
❑ 40 Nm + 90°
❑ Gearbox bracket to gearbox
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always renew
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 - Gearbox bracket
❑ Removing and installing ⇒ page 132
10 - Gearbox mounting
❑ Removing and installing ⇒ page 128
❑ Attach to gearbox bracket
11 - Bolt
❑ 40 Nm + 90°
❑ Gearbox mounting to body

4. Exploded view - assembly mountings 127

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ Tightening sequence ⇒ page 128

❑ 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. 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.

4.1 Removing and installing gearbox

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

128 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 .

– Press release tab -arrow- and remove cover -1- over battery.
– With ignition switched off, disconnect and remove battery ⇒
Electrical system; Rep. gr. 27 .
– Remove air cleaner housing ⇒ Rep. gr. 24 .

– Remove bolts -arrows- and take out battery mounting -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.
– 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 lifting eye.
– Take up weight of engine evenly with spindle; do not lift.

4. Exploded view - assembly mountings 129

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Remove bolts -arrows-.

– Open retainers for wiring duct -arrows-.

– Cut open cable tie -1- and push electrical wiring to one side.
– Unclip wiring duct.

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

Installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in reverse sequence;
permitted unless authorised note
by AUDIthe
AG. following:
AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Tightening torques ⇒ page 127
– Fit gearbox mounting -A- with new bolts -1- to longitudinal
member.

130 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 to gearbox bracket
-arrows-.
– Adjust assembly mountings ⇒ Engine, mechanics; Rep. gr.
10 .
– Detach support bracket -10 - 222 A- from engine.
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .
– Install battery tray and unless
battery ⇒ Electrical
by AUDI AG. system; Rep. gr.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised AUDI AG does not guarantee or accept any liability
27 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install air cleaner housing ⇒ Rep. gr. 24 .

4.2 Removing and installing pendulum sup‐

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

4. Exploded view - assembly mountings 131

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 127

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

-arrow C-, then on subframe -arrow A-.
Audi A3 Cabriolet
– Install noise insulation (centre) ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .

4.3 Removing and installing gearbox brack‐

et
Special tools and workshop equipment required
♦ Support bracketProtected
-10 - 222 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

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 .

132 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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. 24 .

– 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.
– RemoveProtected
front left wheel.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
– Turn steering to the
with respect left.
to the correctness of information in this document. Copyright by AUDI AG.

4. Exploded view - assembly mountings 133

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

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 -arrows- at left mounting from gearbox mount‐

ing.

134 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 127)

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

– Bolt support arm ofwithgearbox mounting

correctness onto gearboxin this bracket
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the of information document. Copyright by AUDI AG.
using new bolts -arrows-. Tightening torque
⇒ Item 12 (page 128)
– Adjust assembly mountings ⇒ Engine, mechanics; Rep. gr.
10 .
– Detach support bracket -10 - 222 A- from engine.

4. Exploded view - assembly mountings 135

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 127

– 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 Protected
system; by Rep. gr.
copyright. Copying for private or commercial purposes, in part or in whole, is not
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.
– Install air cleaner housing ⇒ Rep. gr. 24 .
– Install engine cover panel ⇒ Engine, mechanics; Rep. gr. 10 .

136 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

5 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:
Carry out the steps described in the chapters specified below in
the following order:
• ⇒ „5.1 Preparations“, page 137
• ⇒ „5.2 Draining off gear oil“, page 139
• ⇒ „5.3 Filling up with gear oil“, page 139

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)
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.
5.1 Preparations
Gear oil specification for manual gearboxes ⇒ Electronic parts
catalogue
– Remove air cleaner housing ⇒ Rep. gr. 24 .

5. Checking gear oil level and filling up with gear oil 137
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Vehicles with 2.0 ltr. FSI engine:

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

Vehicles with 1.8 ltr. FSI engine:

– Remove noise insulation (centre) by releasing fasteners
-1 and 2-.

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

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
A pivot pin for the selector forks in the gearbox must be re‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

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 of the selector mechanism.

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.

138 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

5.2 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 138 .
– 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 145) .

– Fit oil drain plug -arrow 1- ⇒ Item 17 (page 175) .

– Now turn angled rod -A- back to original position (direction of
-arrow-) so that selector shaft can move freely again.

5.3 Filling up with gear oil

Add gear oil to container until amount of gear oil in container is
1.9 ltr.
For gear oil specification, refer to ⇒ 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 -F4- and
fill gearbox with gear oil.
– Re-install reversing light switch -F4- -arrow-
⇒ Item 2 (page 184) .
– Install complete air cleaner housing ⇒ Rep. gr. 24 .
– Install noise insulation ⇒ 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.

5. Checking gear oil level and filling up with gear oil 139
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6 Dismantling and assembling gearbox

6.1 General layout of gearbox

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Gearbox housing cover
8 - Gearbox housing
❑ Servicing ⇒ page 174
9 - Selector mechanism
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ (Selector forks)
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 assem‐
bling ⇒ page 187
10 - Reverse gear wheel
11 - Clutch housing
❑ Servicing ⇒ page 174
12 - Input shaft
❑ Dismantling and assem‐
bling ⇒ page 194
13 - Output shaft
❑ Dismantling and assem‐
bling ⇒ page 209
14 - Differential

140 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6.2 Exploded view - dismantling and assembling gearbox

Assembly sequence - removing and installing gearbox housing
cover and 5th/6th gear ⇒ page 148
Assembly sequence - dismantling and assembling complete
gearbox ⇒ page 154

I - Removing and installing

gearbox housing cover and
5th/6th gear ⇒ page 142
II - Removing and installing
gearbox housing and selector
mechanism ⇒ page 145
III - Removing and installing in‐
put shaft, output shaft, differ‐
ential and selector forks
⇒ page 146

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. Dismantling and assembling gearbox 141

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6.3 Exploded view - removing and installing gearbox housing cover and 5th/6th
gear

1 - Gearbox housing
❑ Pulling off together with
5th/6th gear
⇒ page 154
❑ Servicing ⇒ page 174
2 - 5th gear wheel
❑ Pulling off individually
⇒ page 148
❑ Pulling off together with
gearbox housing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 154unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Sleeve
4 - 6th gear wheel
❑ Pulling off individually
⇒ page 148
❑ Pulling off together with
gearbox housing
⇒ page 154
5 - Roller bearing inner race
❑ For output shaft
❑ Mark before removing
❑ Do not interchange with
roller bearing inner race
for input shaft
❑ Larger outer diameter
on gearboxes manufac‐
tured from 21 08 6 on‐
wards
❑ Allocation ⇒ page 144
6 - Bolt
❑ For output shaft
❑ On gearboxes manufac‐
tured up to 20 08 6:
tighten to 40 Nm and turn 180° further
❑ On gearboxes manufactured from 21 08 6 onwards: tighten to 80 Nm and turn 90° further
❑ Allocation of bolts ⇒ page 144
❑ Self-locking
❑ Always renew
❑ Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing 5th/6th gear
synchro-hub and 6th gear wheel. Otherwise there is a risk that the bolts will shear off
7 - Gearbox housing cover
❑ With roller bearings for input and output shafts
❑ Roller bearings for input and output shafts with larger outer diameter on gearboxes manufactured from
21 08 6 onwards ⇒ page 182
❑ Servicing ⇒ page 180
8 - Bolt
❑ 18 Nm
❑ 5x
❑ For gearbox housing cover

142 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

9 - Bolt
❑ For input shaft
❑ On gearboxes manufactured up to 20 08 6: tighten to 40 Nm and turn 180° further
❑ On gearboxes manufactured from 21 08 6 onwards: tighten to 80 Nm and turn 90° further
❑ Allocation of bolts ⇒ page 144
❑ Self-locking
❑ Always renew
❑ Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing 5th/6th gear
synchro-hub and 6th gear wheel. Otherwise there is a risk that the bolts will shear off.
10 - Roller bearing inner race
❑ For input shaft
❑ Mark before removing
❑ Do not interchange with roller bearing inner race for output shaft
❑ On gearboxes manufactured from 21 08 6 onwards, thrust washer and roller bearing inner race are one
component ⇒ Item 12 (page 143)
❑ Allocation of roller bearing inner race ⇒ page 144
11 - Thrust washer
❑ On gearboxes manufactured up to 20 08 6
12 - Roller bearing inner race with thrust washer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For input shaftunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
❑ On gearboxes manufactured from 21 08 6 onwards
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Allocation of roller bearing inner race ⇒ page 144

13 - Sleeve
❑ For 6th gear needle bearing
❑ Renew together with needle bearing
❑ Larger diameter on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
14 - Needle bearing
❑ For 6th gear
❑ Renew together with sleeve
❑ Larger diameter on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
15 - 6th speed selector gear
❑ Modified according to sleeve and needle bearing on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
16 - Corrugated spring washer
❑ Gearboxes manufactured from 26 05 8 onwards
❑ On this version, install only springs for locking pieces which do not have angled ends (as shown in
⇒ page 202 - item 1-)
❑ Select correct components from ⇒ Electronic parts catalogue
17 - 6th gear synchro-ring
18 - Locking collar with synchro-hub for 5th and 6th gear
❑ Pulling off individually ⇒ page 148
❑ Pulling off together with gearbox housing ⇒ page 154
❑ Dismantling and assembling ⇒ page 202 and ⇒ page 203
❑ Locking collar modified on gearboxes manufactured from 12 06 6 onwards ⇒ page 202
❑ Adjusting on gearboxes manufactured up to 11 06 6 ⇒ page 172
❑ Adjusting on gearboxes manufactured from 12 06 6 onwards ⇒ page 173
❑ Installing offset springs for locking pieces ⇒ page 203

6. Dismantling and assembling gearbox 143

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

19 - 5th gear synchro-ring

20 - Corrugated spring washer
❑ Gearboxes manufactured from 26 05 8 onwards
❑ On this version, install only springs for locking pieces which do not have angled ends (as shown in
⇒ page 202 - item 1-)
❑ Select correct components from ⇒ Electronic parts catalogue
21 - 5th speed selector gear
22 - Needle bearing
❑ For 5th gear
23 - Socket head bolt
❑ 25 Nm
❑ For pivot pin to gearbox housing
24 - Pivot pin
25 - 5th/6th gear selector fork
26 - 5th/6th gear selector jaw
27 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 25 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.

Allocation of securing bolts and roller bearing inner races for input
shaft
Gearbox manufac‐ Dimension „a“ (mm) Dimension „b“ (mm)
turing date
Up to 20 08 6 21 31
From 21 08 6 on‐ 23.4 37
wards • In addition: inner
race and thrust
washer are com‐
bined as one
component
-arrow-

Allocation of securing bolts and roller bearing inner races for out‐
put shaft
Gearbox manufac‐ Dimension „a“ (mm) Dimension „b“ (mm)
turing date
Up to 20 08 6 21 31
From 21 08 6 on‐ 23.4 37
wards

144 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6.4 Exploded view - removing and installing gearbox housing and selector
mechanism

1 - Countersunk bolt
❑ 25 Nm
2 - Flange shaft with spring
❑ Removing and installing
⇒ page 233
❑ Assembling
⇒ page 245
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
5 - O-ring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always renew with respect to the correctness of information in this document. Copyright by AUDI AG.

6 - Pivot pin
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 25 Nm
9 - Sealing cap
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
13 - Gearbox housing
❑ Pulling off together with 5th/6th gear ⇒ page 154
❑ Servicing ⇒ page 174
14 - Clutch housing
❑ Servicing ⇒ page 174
15 - Bolt
❑ 25 Nm + 90°
❑ Always renew

6. Dismantling and assembling gearbox 145

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

16 - Selector shaft with selector mechanism cover

❑ (Selector unit)
❑ Servicing ⇒ page 187
17 - Multi-point socket head bolt
❑ 25 Nm

6.5 Exploded view - removing and installing input shaft, output shaft, differential
and selector forks

1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 245
2 - Seal
❑ 4x
❑ Always renew
3 - Output shaft
❑ Dismantling and assem‐
bling ⇒ page 209
4 - Reverse shaft support
❑ Dismantling and assem‐
bling ⇒ page 227
5 - Reverse shaft
❑ With reverse selector
gear
♦ Dismantling and assem‐
bling ⇒ page 227
❑ With locking collar for
reverse gear (on some
gearbox versions, from
gearbox manufacturing
date 09 08 10 onwards) 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
• Dismantling and assem‐ with respect to the correctness of information in this document. Copyright by AUDI AG.

bling ⇒ page 228

6 - Input shaft
❑ Dismantling and assem‐
bling ⇒ page 194
7 - Reverse gear selector fork
❑ Only in conjunction with
reverse selector gear
♦ Dismantling and assem‐
bling ⇒ page 187
❑ Discontinued in conjunction with locking collar for reverse gear
♦ On this version, reverse gear is engaged via selector plate ⇒ Item 7 (page 189)
8 - Torx socket head bolt
❑ 25 Nm
9 - Selector mechanism
❑ (Selector forks)
❑ In conjunction with reverse selector gear
♦ Dismantling and assembling ⇒ page 187

146 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ In conjunction with locking collar for reverse gear (on some gearbox versions, from gearbox manufac‐
turing date 09 08 10 onwards)
♦ Dismantling and assembling ⇒ page 228
10 - Clutch housing
❑ Servicing ⇒ page 174
11 - Nut
❑ 25 Nm + 90°
❑ 4 nuts for bearing mounting
❑ Always renew
12 - Flange shaft with spring
❑ Removing and installing ⇒ page 233
❑ Assembling ⇒ page 245
13 - 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

6. Dismantling and assembling gearbox 147

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6.6 Assembly sequence - removing and installing gearbox housing cover and
5th/6th gear

Note

♦ If only the 5th/6th gear has to be removed, please refer to the procedure described below.
♦ If the gearbox housing has to be removed, please refer to the procedure: Dismantling and assembling
complete gearbox ⇒ page 154 .

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.

148 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-
♦ or two-arm puller -Kukko
20/10- (for 6th gear wheel)

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. Dismantling and assembling gearbox 149

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Support bridge -T10323-

♦ Assembly tool -3253/7-
♦ Press tool -VW 433-
♦ Thrust plate -40 - 105-
♦ Torque wrench -V.A.G
1332-

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
– Remove clutch release lever and release bearing ⇒ page 42 .
• The bearings of the input shaft and output shaft must not be
damaged when removing and installing 5th/6th 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-
• 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-

150 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Secure gearbox on gearbox support -VW 353- .

– Unbolt gearbox housing cover -arrow-.

– Take off cover. If necessary carefully lever up all round and
alternating between sides on the protruding flanges, being
careful not to damage sealing surfaces.

– 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/6th gear
Claws -T10040/2A- foul against: synchro-hub, 6th gear
♦ side of gearbox housing wheel, 5th gear wheel and
gearbox housing have to be
♦ ribs in gearbox housing below removed together
gear wheel ⇒ page 154 .
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
-B- with respect to the correctness of information in this document. Copyright by AUDI AG.
Claws -T10040/2A- foul against
ribs in gearbox housing below 5th
gear wheel.

If claws -T10040/2A- can be applied correctly:

5th and 6th gear can be removed separately ⇒ page 152

6. Dismantling and assembling gearbox 151

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Removing 5th and 6th gear separately

– Remove 5th/6th gear selector fork as follows:
– Cover openings in gearbox housing with a cloth.
– Engage 5th gear (arrows -1- and -2-).
– Remove 5th/6th gear selector jaw (bolt -A-).
– Then remove both bolts -B- for pivot pins.
– Pull out pivot pins. 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
– Take out 5th/6th gearwith
selector
respect tofork.
the correctness of information in this document. Copyright by AUDI AG.

– Remove bolts -A- for inner bearing races on input and output
shafts. To do this, engage 5th gear -arrow 1- and 1st gear
-arrow 2 - and -arrow 3-.
– The input and output shafts are both locked when these two
gears are engaged. The two bolts can now be loosened.

Note

If the shafts are not being renewed, clean residual locking com‐
pound out of tapped holes using a thread tap.

– Pull off 6th gear wheel and roller bearing inner race for output
shaft.
A - Two-arm puller , e.g. -Kukko 20/10-
B - Hexagon bolt, M10 x 20, 17 mm or thrust piece -T10040/3-

Note

6th gear wheel and roller bearing inner race can also be pulled
out using two-arm puller -T10040- and claws -T10040/2A- .

– If necessary, heat gear wheel using hot air blower -

V.A.G 1416- before pulling off.
Pull off 6th speed selector gear with roller bearing inner race for
input shaft, thrust washer and 6th gear synchro-ring, or pull off
together with 5th/6th gear synchro-hub with inner race for 6th gear
needle bearing and 5th gear synchro-ring.
Use puller -T10309- .

152 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– First insert shell half -T10309/1- between output shaft -A- and
mounting for 5th/6th gear selector fork -B-.
• Shell half -T10309/1- must be positioned underneath synchro-
ring.
– 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 by
Protected -T10309/2-
copyright. Copying for private or commercial purposes, in part or in whole, is not
onto tool. 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.
– Please check synchro-hub for damage after removal.
– Renew synchro-ring.

Note

On gearboxes manufactured from 26 05 8 onwards one corruga‐

ted spring washer is fitted below 5th gear synchro-ring and one
above 6th gear synchro-ring ⇒ Item 20 (page 144) and
⇒ Item 16 (page 143) . Check corrugated spring washers for
damage.

– Now take off sleeve from 5th gear wheel.

– Pull off 5th gear wheel.

– First fit claws -A-.
-B- = thrust piece -T10040/3-
or
Thrust plate -40 - 105-

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 ⇒ page 168 .
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
cover for gearbox housing.
– Install gearbox housing cover ⇒ page 142 .
– Install clutch release lever and release bearing ⇒ page 42 .
– Fill up gear oil ⇒ page 100 .

6. Dismantling and assembling gearbox 153

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

6.7 Assembly sequence - dismantling and

assembling complete gearbox
Removing and installing cover for gearbox housing, gearbox
housing, 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.

154 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

6. Dismantling and assembling gearbox 155

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Support bridge -T10323-

♦ Assembly tool -3253/7-
♦ Press tool -VW 433-
♦ Torque wrench -V.A.G
1332-

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.

♦ Counterhold tool -3435-

156 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ -2- Puller -Kukko 18/1- (2x)

♦ Inductive heater -VAS 6414-

♦ Stud M8 x 100 mm
Dismantling
Protected by copyright. complete gearbox
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
– respect
with Mount gearbox
to the correctnesson assembly
of information in thisstand.
document. Copyright by AUDI AG.

– Place drip tray underneath.

– Unscrew oil filler plug and oil drain plug.
– Drain off gear oil.
– Remove clutch release lever and release bearing ⇒ page 42 .
– Remove guide sleeve ⇒ page 42 .

6. Dismantling and assembling gearbox 157

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

• The bearings of the input shaft and output shaft must not be
damaged when removing and installing 5th/6th 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-

– Unbolt gearbox housing cover -arrow-.

– Take off cover. If necessary carefully lever up all round and
alternating between sides on the protruding flanges, being
careful not to damage sealing surfaces.

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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 5th/6th gear selector fork as follows:

– Engage 5th gear (arrows -1- and -2-).
– Remove 5th/6th gear selector jaw (bolt -A-).
– Then remove both bolts -B- for pivot pins.
– Pull out pivot pins.
– Take out 5th/6th gear selector fork.

158 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Remove bolts -A- for inner bearing races on input and output
shafts. To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2 and 3-.
– The input and output shafts are both locked when these two
gears are engaged. The two bolts can now be loosened.

Note

If the shafts are not being renewed, clean residual locking com‐
pound out of tapped holes using a thread tap.

– Remove both bolts -arrows- for reverse shaft support.

– Now remove 3rd bolt -arrow- for reverse shaft support.

– Gearbox for vehicles with start/stop system: remove gearbox

neutral position sender -G701- -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.

6. Dismantling and assembling gearbox 159

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.

– Remove pivot pins -A- on top side of gearbox and bolts -B-
securing gearbox housing to clutch housing (near differential).

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bolts -A- securing gearboxwith
housing
respect to from insideofclutch
the correctness information in this document. Copyright by AUDI AG.
housing.

Note

Do not remove nuts -B- for output shaft bearing mounting.

160 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

Pull off the following components, together with the gearbox

housing:
♦ Synchro-hub for 5th/6th gear
♦ 6th gear wheel
♦ 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.

6. Dismantling and assembling gearbox 161

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Attach pullers Kukko 18/1 -A-.

– Pull off 5th/6th gear synchro-hub, 6th gear wheel, 5th gear
wheel and gearbox housing by alternately tightening spindles
-A- of pullers Kukko 18/1 , 1/2 turn at a time.
– If necessary, heat 5th gear wheel and 6th gear wheel using
hot air blower -V.A.G 1416- slightly before pulling off.

– Remove nuts -B- for output shaft bearing mounting.

– Remove selector forks -A- together with selector plates.

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 with reverse selector gear -arrow-

– Unscrew bolt -B- for reverse gear selector mechanism (see
previous illustration).

162 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Remove reverse gear -A-, input shaft-B- and output shaft -C-
one after the other from clutch housing.

Gearbox with locking collar for reverse gear -arrow-

– Detach input shaft -1-, output shaft -2- and reverse shaft -3-
together from clutch housing.
Continued for all vehicles:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Take out differential. 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 gearbox
– Fit differential.

– Always renew seals -arrows- for output shaft bearing mount‐

ing.

Note

The illustration only shows 3 of the 4 seals.

– Install reverse gear selector mechanism.

6. Dismantling and assembling gearbox 163

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Gearbox with reverse selector gear -arrow-

– Insert input shaft -1- and output shaft -2- together.

– Tighten nuts for output shaft bearing mounting to torque
⇒ Item 11 (page 147) .
– 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 227 ; 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).
– Fit reverse shaft support on reverse shaft.

– 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.

164 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Tighten bolt -A- for reverse gear selector mechanism to speci‐

fied torque ⇒ Item 8 (page 146) .
– Install selector forks -B- together with selector plates.
Pin on reverse shaft support -C- is located in front of selector
plates.

Gearbox with locking collar for reverse gear -arrow-

• Clean locking fluid residue from all tapped holes in reverse

shaft support (residue can be removed using a tap).
• Position input shaft -1-, output shaft -2- and reverse shaft -3-
together on a workbench or similar as shown in illustration.
• The input shaft -1- is held in position by counterhold tool
-3435- .
• The dog teeth -arrow- of the locking collar for reverse gear face
the reverse selector gear.

– Install input shaft -1-, output shaft -2- and reverse shaft -3-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
together. 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 output shaft -2- will contact the differential.
– If necessary, turn differential (2nd mechanic required) so that
output shaft -2- can be inserted into clutch housing.
– Tighten nuts for output shaft bearing mounting to specified
torque ⇒ Item 11 (page 147) .

6. Dismantling and assembling gearbox 165

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Install selector forks -A- together with selector plates.

Reverse shaft support -B- is located in front of selector plates.
• The selector plate for reverse gear engages in the locking col‐
lar for reverse gear -arrow-.

Continued for all vehicles:

– 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.

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.

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.

166 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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.

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 shaft cover ⇒ Item 17 (page 146) .
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 for vehicles with start/stop system: fit gearbox neutral
position sender -G701- -arrow- and tighten securing bolt to
specified torque ⇒ Item 11 (page 145) .

– Install both flange shafts with springs, thrust washers and ta‐
pered rings ⇒ page 245 .

6. Dismantling and assembling gearbox 167

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Install 5th and 6th gears 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-.

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.

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 ➤
6-speed manual gearbox 02S - Edition 02.2011

Checking 5th and 6th gear synchro-rings

– Before re-installing selector gears and synchro-rings for 5th
and 6th gears, press synchro-rings onto tapered seats of se‐
lector gears and measure gap -a- with a feeler gauge.
Gap -a- Installation depth Wear limit
5th/6th gear 1.1 … 1.7 mm 0.5 mm
– Install 5th speed selector gear with needle bearing.
On gearboxes manufactured from 26 05 8 onwards: fit corrugated
spring washer on 5th speed selector gear ⇒ Item 20 (page 144) .
– Fit 5th gear synchro-ring on selector gear.
– If previously dismantled, assemble 5th/6th gear synchro-hub/
locking collar before installing ⇒ page 202 , ⇒ page 203 and
⇒ page 203 .
– Also note modifications to 5th/6th gear locking collar on gear‐
boxes manufactured from 12 06 6 onwards ⇒ page 202 .
These modifications are particularly important when adjusting
5th/6th gear at a later stage.

Installation position of 5th/6th gear synchro-hub/locking collar

Collar -arrow 1- faces towards 6th gear.
The retainers -arrow 2- on the synchro-hub align with the cast
locking pieces on the synchro-ring (arrows in the illustration be‐
low).

5th and 6th gear synchro-rings with cast locking pieces -arrows-
– Cover all openings with a cloth to prevent dirt etc. from entering
the gearbox.

– Heat 5th/6th gear synchro-hub and drive on.

WARNING

Wear protective gloves.

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.
When driving on, ensure clearance for synchro-ring.

6. Dismantling and assembling gearbox 169

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Heat needle bearing inner race for 6th speed selector gear to
100°C (maximum) and drive onto input shaft.

WARNING

Wear protective gloves.

– Fit 6th gear synchro-ring.

On gearboxes manufactured from 26 05 8 onwards: fit corrugated
spring washer on 6th speed synchro-ring ⇒ Item 16 (page 143) .
– Install 6th speed selector gear with needle bearing.

On gearboxes manufactured up to 20 08 6
– Fit thrust washer -A-.

Note

Do not interchange roller bearing inner races of input and output

shafts.

– Heat roller bearing inner race -B- to 100°C (maximum) and

drive onto input shaft.

WARNING

Wear protective gloves.

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.

On gearboxes manufactured from 21 08 6 onwards

Roller bearing inner race -B- and thrust washer -A- are one com‐
ponent.
– Heat roller bearing inner race to 100°C (maximum) and drive
onto input shaft.

WARNING

Wear protective gloves.

Continued for all vehicles:

– Fit sleeve -A- on 5th gear wheel.

Installation position of 6th gear wheel:

• Groove -B- points towards drift sleeve -VW 244 B- .

170 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

»or«
• Groove -arrow 1- in area of shoulder -arrow 2- points towards
drift sleeve -VW 244 B- (see previous illustration).
– Heat 6th gear wheel to 100°C (maximum) and press on.

WARNING

Wear protective gloves.

– Set locking collar for 5th/6th gear to neutral position to allow

6th speed selector gear to turn while pressing on 6th gear
wheel.
– Drive on 6th gear wheel, making sure that it meshes properly
with 6th speed selector gear.

– Heat roller bearing inner race -A- to 100°C (maximum) and

drive onto output shaft.

WARNING

Wear protective gloves.

– Loosen support for input 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.

6. Dismantling and assembling gearbox 171

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– If not already done, remove residual locking fluid from threa‐

ded holes for securing bolts -A- using a thread tap. Otherwise
there is a risk that the bolts will shear off.
Note allocation of securing bolts ⇒ page 144 and ⇒ page 144 .
– Tighten securing bolts for synchro-hub and 5th/6th gear
wheels to torque ⇒ page 142 .
– Engage 2 gears -arrows 1- to -3- in order to tighten securing
bolts -A-.
– Install 5th/6th gear selector fork.

Adjusting 5th/6th gear up to gearbox manufacturing date 11 06 6

– Engage 5th gear.
– Loosen bolt -1-.
– Insert two feeler gauges -A- of 0.5 mm above the two detent
segments -arrows- (for 6th gear) into locking collar.
– Press down selector jaw and locking collar -arrows- and tight‐
en bolt -1- to 25 Nm.

• The 5th gear is engaged.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Checking adjustment: it should just be
permitted unless possible
authorised toAG.
by AUDI insert
AUDI AGandoes not guarantee or accept any liability
0.5 mm feeler gauge between the locking collar and each of
with respect to the correctness of information in this document. Copyright by AUDI AG.

the two detent segments -arrow- on the 6th gear side.

– Repeat adjustment if necessary.
– First engage 5th and then 6th gear.
• There should be slight play between 5th/6th gear selector fork
and selector jaw with 5th or 6th gear engaged.
• Disengage gear.
• Locking collar should now be in the neutral position. Synchro-
ring should move freely.
– Select all gears.

172 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Adjusting 5th/6th gear from gearbox manufacturing date 12 06 6

onwards
– Engage 5th gear.
– Loosen bolt -1-.
– Press down selector jaw and locking collar -arrows- and tight‐
en bolt -1- to 25 Nm.

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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.

• The 5th gear is engaged.

• Checking adjustment: it must not be possible to insert an
0.2 mm feeler gauge between the locking collar and the two
detent segments -arrow- on the 6th gear side.
– Repeat adjustment if necessary.
– First engage 5th and then 6th gear.
• There should be slight play between 5th/6th gear selector fork
and selector jaw with 5th or 6th gear engaged.
– Disengage gear.
• Locking collar should now be in the neutral position. Synchro-
ring should move freely.
– Select all gears.
Continued for all vehicles:
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
cover for gearbox housing.
– Install gearbox housing cover ⇒ page 142 .
– Install release bearing guide sleeve ⇒ page 42 .
– Install clutch release lever and release bearing ⇒ page 42 .
– Fill up gear oil ⇒ page 100 .

6. Dismantling and assembling gearbox 173

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

7 Exploded view - gearbox housing and clutch housing

1 - Gearbox housing
❑ If renewed: Adjust input
shaft and differential
⇒ page 244
2 - Needle bearing
❑ For output shaft
❑ Removing ⇒ page 177
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installing and securing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 178 with respect to the correctness of information in this document. Copyright by AUDI AG.

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)
♦ 2.1 ltr.
❑ Capacity of manual
gearbox (gearbox parti‐
ally dismantled)
⇒ page 137
♦ 1.9 ltr.
4 - Tapered roller bearing outer
race
❑ For output shaft
❑ Removing and installing
⇒ page 215
❑ If renewed: Adjust out‐
put shaft ⇒ page 222
5 - Shim
❑ For output shaft
❑ Table of adjustments ⇒ page 244
6 - Shim
❑ For input shaft
❑ Table of adjustments ⇒ page 244
7 - Tapered roller bearing outer race
❑ For input shaft
❑ Removing and installing ⇒ page 199
❑ If renewed: Adjust input shaft ⇒ page 203
8 - Tapered roller bearing outer race
❑ For input shaft
❑ Removing and installing ⇒ page 201
❑ If renewed: Adjust input shaft ⇒ page 203
9 - Needle bearing
❑ Removing and installing ⇒ page 231

174 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

10 - Dowel sleeve
❑ 2x
11 - Clutch housing
❑ If renewed: table of adjustments ⇒ page 244
12 - Guide sleeve
❑ With input shaft oil seal and vulcanised O-ring
❑ Driving out oil seal ⇒ page 178
❑ Driving in oil seal ⇒ page 178
❑ Remove guide sleeve in order to renew oil seal
❑ If O-ring is damaged, renew both guide sleeve and O-ring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Socket head 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.
❑ 20 Nm
14 - Oil seal
❑ Renewing ⇒ page 233
15 - Sleeve
❑ For oil seal (item ⇒ Item 14 (page 175) )
❑ Removing ⇒ page 178
❑ Installing ⇒ page 179
16 - One-piece oil seal and sleeve
❑ If oil seal is damaged, renew both sleeve and oil seal
❑ Removing ⇒ page 179
❑ Installing ⇒ page 179
17 - Oil drain plug
❑ 35 Nm
18 - Tapered roller bearing outer race
❑ For differential
❑ Pressing out and pressing in ⇒ page 245
❑ If renewed: adjust differential ⇒ page 253
19 - Magnet
❑ Held in place by joint surface of housing
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 179
21 - Tapered roller bearing outer race
❑ For differential
❑ Pressing out and pressing in ⇒ page 245
❑ If renewed: adjust differential ⇒ page 253
22 - Shim
❑ For differential
❑ Table of adjustments ⇒ page 244
23 - Oil seal
❑ Renewing ⇒ page 233

7. Exploded view - gearbox housing and clutch housing 175

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

7.1 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-
♦ Tube -VW 415 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
♦ Press tool -VW 454- with respect to the correctness of information in this document. Copyright by AUDI AG.

176 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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; identification
⇒ page 235 )
♦ Multi-purpose tool -
VW 771- (for one-piece oil
seal and sleeve; identifica‐
tion ⇒ page 235 )
♦ Puller hook -VW 771/37-
(for one-piece oil seal and
sleeve; identification
⇒ page 235 )

♦ Thrust piece -
T10148- (for one-
piece oil seal and
sleeve; identification
⇒ page 235 )

Driving out needle bear‐

ing

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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. Exploded view - gearbox housing and clutch housing 177

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

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)

Lever out sleeve -arrow- with screwdriver

178 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Installing sleeve
– Clean seat of sleeve 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
-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.

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- .

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

If gearbox has been dismantled, press in sleeve onto stop using

thrust piece -T10148- .

Installing oil collector -A- in gearbox housing

– Insert oil collector simultaneously into bore -arrow 1- and
groove -arrow 2-.

7. Exploded view - gearbox housing and clutch housing 179

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

8 Exploded view - gearbox housing cover

1 - Roller bearing
❑ For input shaft
❑ Do not interchange with
roller bearing for output
shaft
❑ Pulling out ⇒ page 181
❑ Larger diameter on
gearboxes manufac‐
tured from 21 08 6 on‐
wards ⇒ page 182
❑ Pressing in on gearbox‐
es manufactured up to
20 08 6: ⇒ page 182
❑ Pressing in on gearbox‐
es manufactured from
21 08 6 onwards:
⇒ page 182
❑ Securing ⇒ page 183
2 - Roller bearing
❑ For output shaft
❑ Do not interchange with
roller bearing for input
shaft
❑ Larger diameter on
gearboxes manufac‐
tured from 21 08 6 on‐
wards ⇒ page 182
❑ Pulling out ⇒ page 182
❑ Pressing in on gearbox‐
es manufactured up to
20 08 6: ⇒ page 182
❑ Pressing in on gearbox‐
es manufactured from
21 08 6 onwards:
⇒ page 182
❑ Securing ⇒ page 183
3 - Gearbox housing cover
❑ Modified according to roller bearings on gearboxes manufactured from 21 08 6 onwards ⇒ page 182
4 - Magnet
❑ From 11.2010 onwards Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Can only be fitted in a cover withpermitted
a recess -arrow-
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 - Clip
❑ Holds magnet in position

180 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

8.1 Servicing gearbox housing cover

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Support bridge -2011-
♦ -1- internal puller -Kukko
21/5-
♦ -4- Counter-support -Kukko
22/1-
♦ In addition for gearboxes
manufactured from 21 08 6
onwards: assembly toolProtected 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
-3348/2- with respect to the correctness of information in this document. Copyright by AUDI AG.

Pulling roller bearing out of gearbox housing cover

A - Internal puller 30 ... 37 mm , e.g. -Kukko 21/5-
B - Counter-support , e.g. -Kukko 22/1-

8. Exploded view - gearbox housing cover 181

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Pulling roller bearing out of gearbox housing cover

A - Internal puller 30 ... 37 mm , e.g. -Kukko 21/5-
B - Counter-support , e.g. -Kukko 22/1-

Allocation of roller bearings

Gearbox manufac‐ Dimension „a“ (mm) Dimension „b“ (mm)
turing date
Up to 20 08 6 43 43
From 21 08 6 on‐ 47 47
wards

Pressing roller bearings into gearbox housing cover on gearboxes

manufactured up to 20 08 6
– Heat area round bearing seats in gearbox housing cover to
approx. 100°C using hot air blower -V.A.G 1416- .
– Insert roller bearing after heating housing and push into posi‐
tion under workshop press until heat exchange has taken
place.

Note

Roller bearings must be pressed fully home into cover.

Pressing roller bearings into gearbox housing cover on gearboxes

manufactured from 21 08 6 onwards
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Heat area round bearing seats in gearbox housing
permitted unless cover
authorised to AG. AUDI AG does not guarantee or accept any liability
by AUDI
approx. 100°C using hot air blower -V.A.G 1416-
with respect to the .correctness of information in this document. Copyright by AUDI AG.

– Insert roller bearing after heating housing and push into posi‐
tion under workshop press until heat exchange has taken
place.

Note

Roller bearings must be pressed fully home into cover.

182 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Secure roller bearings in gearbox housing cover by peening

-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.

8. Exploded view - gearbox housing cover 183

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

9 Exploded view - servicing selector unit

1 - Selector unit
❑ Consists of selector
shaft and selector
mechanism cover
❑ Components cannot be
separated from each
other
❑ Dismantling and assem‐
bling ⇒ page 185
2 - Reversing light switch -F4-
❑ 20 Nm
❑ Lightly coat lug with
MoS2 grease
3 - Locking pin
❑ For adjusting selector
mechanism
❑ Removing ⇒ page 185
❑ Pressing in
⇒ page 186
4 - Gate relay lever
❑ Installation position
⇒ page 79
❑ Plastic version from
model year 2008 on‐
wards
5 - Bearing bush
❑ Not required for plastic
gate relay lever
6 - Oil seal
❑Protected
Leverby out with screw‐
driverunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted
❑ with
Installing
respect to ⇒
thepage 186of information in this document. Copyright by AUDI AG.
correctness

7 - Nut
❑ Tightening torque ⇒ Item 18 (page 77)
❑ Self-locking
❑ Always renew
8 - Gearbox selector lever
❑ Install so that gap in splines aligns with selector shaft ⇒ page 186
❑ Can be renewed with selector mechanism installed
❑ Installation position ⇒ page 79
9 - Cap
❑ For gearbox breather
10 - Securing clip
❑ Not required for plastic gate relay lever
11 - Cover plate
12 - Spring
❑ Not fitted on all gearboxes

184 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

9.1 Dismantling and assembling selector

unit
Special tools and work‐
shop equipment re‐
quired
♦ Tube -T10203-

♦ Tube -VW 423-

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 locking pin

-A- from selector mecha‐
nism cover
– Remove outer part of
retaining pin.
– Then lever out lock‐
ing pin carefully using
a screwdriver.

9. Exploded view - servicing selector unit 185

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

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.

186 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

10 Exploded view - selector forks

♦ ⇒ „10.1 Exploded view - selector forks in conjunction with re‐
verse selector gear arrow “, page 187
♦ ⇒ „10.2 Exploded view - selector forks in conjunction with
locking collar for reverse gear arrow “, page 189
♦ ⇒ „10.3 Dismantling and assembling selector forks“,
page 190

10.1 Exploded view - selector forks in con‐

junction with reverse selector gear
-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.

Note

The selector fork cluster ( ⇒ Item 7 (page 188) ) does not have to be dismantled in order to remove and install
detent segments, lock washers and angular contact ball bearings.

10. Exploded view - selector forks 187

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

1 - 5th/6th gear detent seg‐

ment
❑ Identification
⇒ page 191
❑ Detent segment should
turn freely after lock
washer is installed
2 - Lock washer
❑ Always renew
❑ Removing ⇒ page 192
❑ Installing ⇒ page 192
3 - 5th/6th gear selector fork
4 - Bolt
❑ 25 Nm
5 - 5th/6th gear selector jaw
6 - Angular contact ball bearing
❑ 4x
❑ Removing ⇒ page 192
❑ Pressing inner race into
outer race ⇒ page 192
❑ Installing ⇒ page 193
7 - Selector fork cluster with
selector plates
8 - 1st/2nd gear detent seg‐
ment
❑ Identification
⇒ page 191
❑ The segment must ro‐
tate freely after installing
the lock washerProtected 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
9 - 3rd/4th gear detentwithseg‐
respect to the correctness of information in this document. Copyright by AUDI AG.
ment
❑ Identification ⇒ page 191
❑ 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

188 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

10.2 Exploded view - selector forks in con‐

junction with locking collar for reverse
gear -arrow-

Note

The selector fork cluster ( ⇒ Item 7 (page 189) ) does not have to be dismantled in order to remove and install
detent segments, lock washers and angular contact ball bearings.

1 - 5th/6th gear detent seg‐

ment
❑ Identification
⇒ page 191
❑ Detent segment should Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
turn freely after lock permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
washer is installed with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Lock washer
❑ Always renew
❑ Removing ⇒ page 192
❑ Installing ⇒ page 192
3 - 5th/6th gear selector fork
4 - Bolt
❑ 25 Nm
5 - 5th/6th gear selector jaw
6 - Angular contact ball bearing
❑ 4x
❑ Removing ⇒ page 192
❑ Pressing inner race into
outer race ⇒ page 192
❑ Installing ⇒ page 193
7 - Selector fork cluster with
selector plates
❑ With selector plate for
reverse gear selector
mechanism -arrow-
8 - 1st/2nd gear detent seg‐
ment
❑ Identification
⇒ page 191
❑ The segment must ro‐
tate freely after installing the lock washer
9 - 3rd/4th gear detent segment
❑ Identification ⇒ page 191

10. Exploded view - selector forks 189

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ The segment must rotate freely after installing the lock washer

10.3 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.

190 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Removal lever -80–

200-

♦ Assembly mandrel
-10 - 508-

♦ Tensioning device
-2070-

Identification of detent
segments
Dimension -a-
1 - Detent segments, 1st/
2nd gear = 11.4 mm
2 - Detent segments,
3rd/4th gear = 7.7 mm
3 - 5th/6th gear detent
segments = 12.1 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.

10. Exploded view - selector forks 191

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-.

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 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.

192 Rep. gr.34 - Controls, housing

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 191

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. Exploded view - selector forks 193

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

35 – Gears, shafts
1 Input shaft
♦ ⇒ „1.1 Exploded view - input shaft“, page 194
♦ ⇒ „1.2 Dismantling and assembling input shaft“, page 197
♦ ⇒ „1.3 Adjusting input shaft“, page 203

1.1 Exploded view - input shaft

Note

♦ Refer to general repair instructions ⇒ page 6 .

♦ 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 244 .

1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Pressing out
⇒ page 199
❑ Pressing in
⇒ page 199
3 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 199
❑ Pressing on
⇒ page 200
4 - Input shaft
❑ Adjusting ⇒ page 203
5 - 3rd gear wheel
❑ Installation position:
Collar faces 4th gear
❑ Pressing off
⇒ page 200
❑ Pressing on
⇒ page 200
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Circlip 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.
❑ Always renew
7 - 4th gear wheel
❑ Pressing off with ta‐
pered roller bearing out‐
er race and sleeve
⇒ page 200
❑ Pressing on
⇒ page 201
❑ Installation position:
Collar faces 3rd gear

194 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

8 - Tapered roller bearing inner race

❑ Pressing off with 4th gear wheel and sleeve ⇒ page 200
❑ Pressing on ⇒ page 201
9 - Thrust washer
10 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 201
❑ Pressing in ⇒ page 202
11 - Shim
❑ Determining thickness ⇒ page 203
12 - Gearbox housing
13 - Sleeve
❑ For 5th gear needle bearing
❑ Press off with 4th gear wheel and tapered roller bearing inner race ⇒ page 200
❑ Pressing on ⇒ page 201
❑ Fit thrust washer ⇒ Item 9 (page 195) before installing
14 - Needle bearing
❑ For 5th gear
15 - 5th speed selector gear
16 - Corrugated spring washer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Gearboxes manufactured frompermitted
26 05 unless
8 onwards
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ On this version, install only springs for locking pieces which do not have angled ends (as shown in
with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 202 - item 1-)

❑ Select correct version from ⇒ Electronic parts catalogue
17 - 5th gear synchro-ring
❑ With cast locking pieces ⇒ page 169
❑ Checking for wear ⇒ page 169
18 - Locking collar with synchro-hub for 5th and 6th gear
❑ Pulling off individually ⇒ page 148
❑ Pulling off together with gearbox housing ⇒ page 154
❑ Dismantling and assembling ⇒ page 202 and ⇒ page 203
❑ Locking collar modified on gearboxes manufactured from 12 06 6 onwards ⇒ page 202
❑ Adjusting on gearboxes manufactured up to 11 06 6 ⇒ page 172
❑ Adjusting on gearboxes manufactured from 12 06 6 onwards ⇒ page 173
❑ Installing offset springs for locking pieces ⇒ page 203
19 - 6th gear synchro-ring
❑ With cast locking pieces ⇒ page 169
❑ Checking for wear ⇒ page 169
20 - Corrugated spring washer
❑ Gearboxes manufactured from 26 05 8 onwards
❑ On this version, install only springs for locking pieces which do not have angled ends (as shown in
⇒ page 202 - item 1-)
❑ Select correct version from ⇒ Electronic parts catalogue
21 - 6th speed selector gear
❑ Modified according to sleeve and needle bearing on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
22 - Needle bearing
❑ For 6th gear

1. Input shaft 195

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ Renew together with sleeve

❑ Larger diameter on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
23 - Sleeve
❑ For 6th gear needle bearing
❑ Renew together with needle bearing
❑ Larger diameter on gearboxes manufactured from 21 08 6 onwards
❑ Select correct components from ⇒ Electronic parts catalogue
24 - Thrust washer
❑ On gearboxes manufactured up to 20 08 6
25 - Roller bearing inner race
❑ Allocation ⇒ page 144
❑ On gearboxes manufactured up to 20 08 6
❑ Mark before removing
❑ Do not interchange with roller bearing inner race for output shaft
26 - Roller bearing inner race with thrust washer
❑ Allocation ⇒ page 144by 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
❑ For input shaft with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ On gearboxes manufactured from 21 08 6 onwards
27 - Bolt
❑ Tightening torque ⇒ Item 9 (page 143)
❑ For input shaft
❑ Allocation of bolts ⇒ page 144
❑ Self-locking
❑ Always renew
❑ Use thread tap to remove any remaining locking fluid from threaded holes for bolts securing 5th/6th gear
synchro-hub and 6th gear wheel. Otherwise there is a risk that the bolts will shear off

196 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

1.2 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-
♦ Thrust plate -VW 402-
♦ 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.

1. Input shaft 197

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Drift sleeve -41 - 501-

♦ Thrust plate -VW 447 i-
♦ Drift sleeve -30 - 100-
♦ Thrust pad -VW 510-
♦ -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.

198 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Thrust plate -
VW 402-

♦ Inductive heater -
VAS 6414-

Pressing out tapered

roller bearing outer race

Pressing in tapered roller bearing 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
Pressing off tapered roller bearing inner race with respect to the correctness of information in this document. Copyright by AUDI AG.

A - Splitter 12 ... 75 mm -Kukko 17/1-

1. Input shaft 199

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Pressing on tapered roller bearing inner race

Pressing off 4th gear wheel with tapered roller bearing 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing off 3rd gear wheel

– First remove circlip.

Heat 3rd gear wheel and press on.

WARNING

Wear protective gloves.

Shoulder faces towards 4th gear.

200 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Heat 4th gear wheel and press on.

WARNING

Wear protective gloves.

Shoulder faces towards 3rd gear.

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.

Pressing on sleeve for 5th gear needle bearing

Pressing out tapered roller bearing outer race

1. Input shaft 201

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Pressing in tapered roller bearing outer race

– Install with shim after adjusting input shaft.

On gearboxes manufactured from 12 06 6 onwards, deeper re‐

cesses in 5th/6th gear locking collar on both sides -arrows-
Dimension -a- On gearboxes man‐ On gearboxes manu‐
(6th gear side) ufactured up to factured from 12 06 6
11 06 6 onwards
1.5 mm 1.8 mm

Dimension -b- On gearboxes man‐ On gearboxes manu‐

(5th gear side) ufactured up to factured from 12 06 6
11 06 6 onwards
1.5 mm 2.0 mm
– Refer to ⇒ Electronic parts catalogue to allocate locking collar
and 5th/6th gear synchro-hub.
Modified adjustment procedure on 5th/6th gears due to the deep‐
er recesses:
– Adjusting 5th/6th gear on gearboxes manufactured up to
11 06 6 ⇒ page 172
– Adjusting 5th/6th gear on gearboxes manufactured from
12 06 6 onwards ⇒ page 173

Dismantling and assembling 5th/6th gear locking collar and syn‐

chro-hub
1- Spring
2- Locking piece
3- Synchro-hub
4- Locking collar
– Slide locking collar over synchro-hub.
The deeper recesses -arrow A- for the locking pieces in the syn‐
chro-hub must align with the recesses -arrow B- in the locking
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
collar. with respect to the correctness of information in this document. Copyright by AUDI AG.

202 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Assembling 5th/6th gear locking collar/synchro-hub

• Locking collar is pushed over synchro-hub.
– Insert locking pieces in the deeper recesses -arrows- and in‐
stall springs 120° off-set. Angled end of spring must locate in
hollow locking piece.

Note

♦ On gearboxes manufactured from 26 05 8 onwards one cor‐

rugated spring washer is fitted below 5th gear synchro-ring
and one above 6th gear synchro-ring ⇒ Item 16 (page 195)
and ⇒ Item 20 (page 195) .
♦ On this version, install only springs for locking pieces which do
not have angled ends (as shown in ⇒ page 202 - item 1-)

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 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-).

1.3 Adjusting input shaft

(Determining thickness of shim for input 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.

1. Input shaft 203

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 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.

Procedure
The input shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Input shaft
♦ 4th gear wheel
or the
♦ Tapered roller bearings for input shaft
Table of adjustments ⇒ page 244
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.

204 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Press tapered roller bearing outer race without shim onto stop
in clutch housing.

– Press tapered roller bearing outer race without shim onto stop
in gearbox housing.
– 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.

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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.

1. Input shaft 205

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

206 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 … 1.549 1.500
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
1.550with
…respect
1.574 to the correctness of information in1.525
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 207

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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- .
– Put on 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 no bearing clearance is measurable, but the input shaft has

perceptible play and 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.

208 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

2 Output shaft
♦ ⇒ „2.1 Exploded view - output shaft“, page 209
♦ ⇒ „2.2 Dismantling and assembling output shaft“, page 212
♦ ⇒ „2.3 Adjusting output shaft“, page 222

2.1 Exploded view - output shaft

Note

♦ The output shaft is dismantled as follows:- Position splitter under 2nd speed selector gear
( ⇒ Item 21 (page 210) ) and press off as described in ⇒ page 216 . Remove circlip
⇒ Item 17 (page 210) . Then press off locking collar and synchro-hub for 1st and 2nd gear as shown in
⇒ page 216 .
♦ Refer to general repair instructions ⇒ page 6 .
♦ 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.

1 - Nut
❑ 25 Nm + 90°
❑ 4 nuts for bearing
mounting
❑ Always renew
2 - Clutch housing
3 - Shim
❑ For output shaft
❑ Table of adjustments
⇒ page 244
4 - Small tapered roller bearing
outer race
❑ Removing ⇒ page 215
❑ Pressing in
⇒ page 215 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 - Small tapered roller bearing with respect to the correctness of information in this document. Copyright by AUDI AG.
inner race
❑ Pulling off ⇒ page 216
❑ Pressing on
⇒ page 216
6 - Output shaft
❑ Adjusting ⇒ page 222
7 - Large tapered roller bearing
inner race
❑ Pulling off ⇒ page 217
❑ Pressing on
⇒ page 217
8 - Seal
❑ Place seals (4x) on bolts
for bearing mounting

2. Output shaft 209

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

9 - Bearing mounting
❑ With large tapered roller bearing outer race and bolts
❑ 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 217
❑ Checking for wear ⇒ page 217
❑ Check lugs for scoring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

14 - Outer ring for 1st gear

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 ⇒ page 217
❑ Checking for wear ⇒ page 218
❑ Renew if scored or if there are visible traces of wear
15 - 1st gear synchro-ring
❑ Installation position ⇒ page 217
❑ Checking for wear ⇒ page 218
16 - Locking collar with synchro-hub for 1st and 2nd gear
❑ Press off together with bearing mounting ⇒ Item 17 (page 210) after removing circlip ⇒ page 216
❑ Dismantling ⇒ page 218
❑ Assembling locking collar/synchro-hub ⇒ page 218 , ⇒ page 218 and ⇒ page 219
❑ Installation position ⇒ page 219
❑ Pressing on ⇒ page 219
17 - Circlip
18 - 2nd gear synchro-ring
❑ Checking for wear ⇒ page 218
❑ Assemble so that the recesses engage on the locking pieces on the locking collar
⇒ Item 16 (page 210)
19 - Outer ring for 2nd gear
❑ Insert in synchro-ring ⇒ Item 18 (page 210)
❑ Installation position ⇒ page 219
❑ Renew if scored or if there are visible traces of wear
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Checking for wear ⇒ page 217
❑ Check lugs for scoring
❑ Installation position ⇒ page 220
21 - 2nd speed selector gear
❑ Installation position ⇒ page 220
22 - Needle bearing
❑ For 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with 2nd speed selector gear ⇒ page 216

210 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ Pressing on ⇒ page 220

25 - Needle bearing
❑ For 3rd gear
26 - 3rd speed selector gear
27 - 3rd gear synchro-ring
❑ Checking for wear ⇒ page 220
28 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Pressing off with 2nd speed selector gear ⇒ Item 21 (page 210) and 3rd speed selector gear
⇒ Item 26 (page 211) ⇒ page 216
❑ Dismantling ⇒ page 221
❑ Assembling locking collar/synchro-hub ⇒ page 221 , ⇒ page 221 and ⇒ page 221
❑ Installation position: Locking collar/synchro-hub ⇒ page 221
❑ Pressing on ⇒ page 222
29 - Sleeve
❑ For 4th gear needle bearing
❑ Pressing off with locking collar and synchro-hub for 3rd and 4th gear ⇒ Item 28 (page 211)
⇒ page 216
❑ Pressing on ⇒ page 222
30 - Needle bearing
❑ permitted
For 4thunless
gear
Protected 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

31 - 4th gear synchro-ring

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

❑ Checking for wear ⇒ page 220

32 - 4th speed selector gear
33 - Thrust washer
34 - Needle bearing
❑ For output shaft
❑ Removing and installing ⇒ page 177
35 - Gearbox housing
36 - Sleeve
❑ For needle bearing/output shaft
❑ Pressing off ⇒ page 216
❑ Pressing on ⇒ page 222
37 - 5th gear wheel
❑ Pulling off individually ⇒ page 148
❑ Pulling off together with gearbox housing ⇒ page 154
38 - Sleeve
39 - 6th gear wheel
❑ Pulling off individually ⇒ page 148
❑ Pulling off together with gearbox housing ⇒ page 154
40 - Roller bearing inner race
❑ For output shaft
❑ Larger outer diameter on gearboxes manufactured from 21 08 6 onwards
❑ Allocation ⇒ page 144
❑ Mark before removing
❑ Do not interchange with roller bearing inner race for input shaft
41 - Bolt
❑ Tightening torque ⇒ Item 6 (page 142)

2. Output shaft 211

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

❑ Allocation of bolts ⇒ page 144

❑ For output shaft
❑ Self-locking
❑ Always renew

2.2 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-
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 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Thrust plate -VW 402-

♦ Thrust piece -32 - 111-
♦ Press tool -VW 409-
♦ Support rails -VW 457-
♦ Tube -VW 519-

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. Output shaft 213

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Drift sleeve -30 - 100-

♦ Tube -VW 415 A-
♦ Thrust plate -VW 447 H-
♦ Press tool -VW 454-
♦ Tube -2040-
♦ Drift sleeve -41 - 501-

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.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ -1- Internal puller -

Kukko 21/6-

♦ -3- Splitter -Kukko

17/2-
♦ -4- Counter-support -
Kukko 22/2-
♦ Inductive heater -
VAS 6414-

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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.

♦ Feeler gauge
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

2. Output shaft 215

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-

Note

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-.

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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.

216 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 inner race.

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
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permitted–unless
Press inner
authorised by ring onto
AUDI AG. tapered
AUDI seat
AG does not on selector
guarantee gear
or accept any and
liability meas‐
ure
with respect gap
to the -a- using
correctness a feeler
of information gauge.
in this document. Copyright by AUDI AG.

Gap -a- Installation depth Wear limit

1st and 2nd gear 0.75 … 1.25 mm 0.3 mm

2. Output shaft 217

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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

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 218
Assembling version used together with solid locking pieces (no
internal recess) ⇒ page 219
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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
end of spring must locate in hollow locking piece. 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.

218 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Heat 1st and 2nd gear locking collar/synchro-hub and press
with respect to the correctness on in this document. Copyright by AUDI AG.
of information

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-.

2. Output shaft 219

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 219 .

Pressing on sleeve for 3rd gear needle bearing

Checking 3rdProtected
and 4th gear synchro-ring
by copyright. Copying for privatefor wear purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Press synchro-ring
with respectonto taperedofseat
to the correctness on selector
information gearCopyright
in this document. and by AUDI AG.
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

220 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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
⇒ page 221
Assembling version used together with solid locking pieces (no
internal recess) ⇒ page 221
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.

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.
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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 221

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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

2.3 Adjusting output shaft

(Determining thickness of output shaft shim)

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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.

222 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-

♦ -2- Puller -Kukko 18/0- (threaded spindle)

2. Output shaft 223

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Adapter -VW 771/15-

Procedure
The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Output shaft
♦ Clutch housing
or
♦ Tapered roller bearings for output shaft
Table of adjustments ⇒ page 244
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 215 .
– 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.

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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.

224 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Mount dial gauge (3 mm measuring range) and set to „0“ with

1 mm preload.
-A- = (threaded spindle) from puller -Kukko 18/0- .
– Move output shaft up and down; read off and note play indi‐
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
– Remove output shaft and pull out small tapered roller bearing
outer race ⇒ page 215 .
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
0.740 … 0.789 0.900
0.790 … 0.839 0.950
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
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Note with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ 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) ⇒ page 215 and install
output shaft.

2. Output shaft 225

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Tighten bearing mounting nuts in clutch housing to 25 Nm and

then turn 90° further.

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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.

226 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3 Reverse shaft
♦ ⇒ „3.1 Exploded view - reverse shaft with reverse selector gear
arrow “, page 227
♦ ⇒ „3.2 Exploded view - reverse shaft with locking collar for re‐
verse gear arrow “, page 228
♦ ⇒ „3.3 Dismantling and assembling reverse shaft“, page 230

3.1 Exploded view - reverse shaft with re‐

verse selector gear -arrow-

Note

After removal, always renew needle bearings in clutch housing and in reverse shaft support.
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with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Reverse shaft 227

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

1 - Clutch housing
2 - Needle bearing
❑ Pulling out ⇒ page 231
❑ Pressing in
⇒ page 231
3 - Reverse gear wheel
4 - Circlip
❑ Always renew after re‐
moving
❑ Fit new circlip carefully
❑ Do not overstretch
5 - Reverse selector gear
❑ Remove circlip before
renewing
❑ Shoulder faces towards
reverse gear wheel
6 - Reverse shaft
❑ Removing and installing
⇒ page 154
7 - Needle bearing
❑ Pressing out
⇒ page 231
❑ Pressing in
⇒ page 232
8 - Reverse shaft support
❑ Removing and installing
⇒ page 154

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3.2 Exploded view - reverse shaft with lock‐

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.

ing collar for reverse gear -arrow-

Note

After removal, always renew needle bearings in clutch housing and in reverse shaft support.

228 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

1 - Clutch housing
2 - Needle bearing
❑ Pulling out ⇒ page 231
❑ Pressing in
⇒ page 231
3 - Reverse shaft
❑ With reverse gear wheel
❑ Removing and installing
⇒ page 154
4 - Reverse gear locking collar
❑ Installation position: dog
teeth face towards re‐
verse selector gear
5 - Thrust washer
6 - Needle bearing
❑ For reverse selector
gear
❑ Lubricate with gear oil
before installing
7 - Reverse selector gear
❑ Installation position: dog
teeth face towards lock‐
ing collar for reverse
gear
8 - Thrust washer
9 - Needle bearing
❑ Pressing out
⇒ page 231
❑ Pressing in
⇒ page 232
10 - Reverse shaft support
❑ Removing and installing ⇒ page 154

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3. Reverse shaft 229

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3.3 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-

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230 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ -1- Internal puller -

Kukko 21/2-

♦ -4- Counter-support -
Kukko 22/1-
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 remov‐
al and must be renewed.

Pressing needle bearing Protected

-A- intobyclutch housing
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 needle bearing out of reverse shaft support

3. Reverse shaft 231

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Pressing needle bearing into reverse shaft support

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

232 Rep. gr.35 - Gears, shafts

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

39 – Final drive - front differential

1 Renewing oil seals for flange shafts
with gearbox installed in vehicle
♦ ⇒ „1.1 Renewing flange shaft oil seal (left-side)“, page 233
♦ ⇒ „1.2 Identification of flange shaft oil seals (right-side)“, page
235
♦ ⇒ „1.3 Renewing flange shaft oil seal (right-side) - two-piece
oil seal and sleeve“, page 236
♦ ⇒ „1.4 Renewing oil seal together with sleeve (one-piece
sleeve and flange shaft oil seal (right-side))“, page 239

1.1 Renewing flange shaft oil seal (left-side)

Special tools and workshop

equipment required
♦ Multi-purpose tool -
VW 771-
♦ Extractor hook -
VW 771/37-
♦ Thrust piece -T10160-
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
♦ 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
♦ Sealing grease -G 052 128
with respect to the correctness of information in this document. Copyright by AUDI AG.
A1-

Removing
• Gearbox in vehicle
– Remove left wheel.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 233
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

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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.

– Pull out flange shaft oil seal using multi-purpose tool -VW 771-
and puller hook -VW 771/37- .

234 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 246)
– 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 137 .
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install front section of wheel housing linerwith
(left-side)
respect to the correctness of information in this document. Copyright by AUDI AG.
-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:
♦ Two-piece oil seal and sleeve
♦ One-piece oil seal and sleeve

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 235
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Two-piece oil seal -1- and sleeve -2-.

• Identification: recesses on sleeve -arrow- all around.
Renewing oil seal ⇒ page 236

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 239 .

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
235
Special tools and workshop equipment required
♦ Lifting tackle -2024 A/1-

♦ Assembly tool -3253/2-

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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.

236 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Thrust piece -T10160-

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

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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.

Removing
• Gearbox in vehicle
– Remove noise insulation (centre) by releasing fasteners
-1 ... 3-.

– Unbolt heat shield for right-side drive shaft -arrows-.

– Turn steering to full right lock.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 237
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Unbolt drive shaft -1- from flange shaft ⇒ Running gear, front-
wheel drive and four-wheel drive; Rep. gr. 40 .
– Lift drive shaft as far as possible and tie in place. Do not dam‐
age surface coating.

Vehicles with 1.8 ltr. TFSI engine:

– Remove right wheel.
– Remove nuts -arrows- on swivel joint (right-side).

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

– Disengage wishbone (right-side) at swivel joint.

– Swivel suspension strut (right-side) outwards and support with
-2024 A /1- as shown in illustration.

WARNING

Secure locking pin and swivel joint with retaining clip -arrow-
and nut -1-.

Continued for all vehicles:

– 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.

238 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– 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 178

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- .

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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.
– 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 246)
– Attach swivel joint to wishbone and secure ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 40 .
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Install heat shield for right-side drive shaft.
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 137 .
– Fit right wheel ⇒ Rep. gr. 44 .
– 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 25

1.4 Renewing oil seal together with sleeve

(one-piece sleeve and flange shaft oil
seal (right-side))
• ⇒ „1.2 Identification of flange shaft oil seals (right-side)“, page
235

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 239
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Special tools and workshop equipment required

♦ Thrust piece -T10148-
♦ Spindle from assembly device -3066-
♦ Multi-purpose tool -VW 771-
♦ Extractor hook -VW 771/37-
♦ Torque wrench -V.A.G 1331-

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

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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.

240 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

• Gearbox in vehicle
Removing
– Remove right wheel.
– Remove noise insulation (centre) by releasing fasteners
-1 ... 3-.

– Unbolt heat shield for right-side drive shaft -arrows-.

– Turn steering to full right lock.

– Unbolt drive shaft -1- from flange shaft ⇒ Running gear, front-
wheel drive and four-wheel drive; Rep. gr. 40 .
– Tie-up drive shaft as high as possible. Do not damage paint
on drive shaft.

Vehicles with 1.8 ltr. TFSI engine:

– Remove nuts -arrows- on swivel joint (right-side).

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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.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 241
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Disengage wishbone (right-side) at swivel joint.

– Swivel suspension strut (right-side) outwards and support with
-2024 A /1- as shown in illustration.

WARNING

Secure locking pin and swivel joint with retaining clip -arrow-
and nut -1-.

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Continued forpermitted
all vehicles:
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.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.
– 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.

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.

242 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

– Press flange shaft in against spring on gearbox housing and

secure with countersunk bolt -arrow-. Tightening torque
⇒ Item 12 (page 246)
– Attach swivel joint to wishbone and secure ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 40 .
– Bolt drive shaft to flange shaft ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 .
– Install heat shield for right-side drive shaft.
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 137 .
– Fit right wheel ⇒ Rep. gr. 44 .
– 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 25

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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.

1. Renewing oil seals for flange shafts with gearbox installed in vehicle 243
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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:

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Input shaft Output
with respect to the correctness of information in this document. Copyright by AUDI AG.
Differential
⇒ page 203 shaft ⇒ page 253
⇒ page 222
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 differ‐ x
ential
4th gear wheel x

244 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3 Differential
♦ ⇒ „3.1 Exploded view - differential“, page 245
♦ ⇒ „3.2 Dismantling and assembling differential“, page 247
♦ ⇒ „3.3 Adjusting differential“, page 253

3.1 Exploded view - differential

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 253 .

1 - Gearbox housing
2 - Shim
❑ For differential
❑ Determining thickness
⇒ page 253
3 - Tapered roller bearing outer
race
❑ Pulling out ⇒ page 250
❑ Pressing in
⇒ page 251
4 - Tapered roller bearing inner
race
❑ Pulling off ⇒ page 250
❑ Pressing on
⇒ page 250
5 - Differential cage
❑ With final drive gear
❑ Differential cage is
matched to one-piece
thrust washer
⇒ page 252
❑ Hole for spring pin is
matched to length of
spring pin ⇒ page 251
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For
permitted unless correct
authorised version,
by AUDI AG. AUDI re‐
AG does not guarantee or accept any liability
with respect tofer to ⇒ Electronic
the correctness parts
of information in this document. Copyright by AUDI AG.
catalogue
6 - Tapered roller bearing inner
race
❑ Pulling off ⇒ page 250
❑ Pressing on
⇒ page 250
7 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 249
❑ Pressing in ⇒ page 250

3. Differential 245
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

8 - Clutch housing
9 - Sleeve
❑ Forms housing for oil seal ⇒ Item 10 (page 246)
❑ Removing and installing ⇒ page 178
10 - Oil seal
❑ Renewing flange shaft oil seal (left-side) ⇒ page 233
❑ Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve ⇒ page 236
11 - One-piece oil seal and sleeve
❑ If oil seal is damaged, renew both sleeve and oil seal ⇒ page 239
12 - Countersunk bolt
❑ 25 Nm
❑ Screws into threaded piece ⇒ Item 20 (page 246)
13 - Flange shaft
❑ Removing and installing ⇒ page 233
14 - Spring for flange shaft
❑ Installed behind flange shafts
15 - Thrust washer
❑ Installation position ⇒ page 253
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 252
19 - Sun wheel
❑ Installing ⇒ page 252
20 - Threaded piece
❑ Installing ⇒ page 252
21 - Differential pinion pin
❑ Drive out with drift
❑ Installing ⇒ page 252
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22 - Spring pin unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Secures differential pinion pin
❑ Spring pins of two different lengths are fitted
❑ Identification of different types of spring pin ⇒ page 251
❑ Short spring pin: removing and installing ⇒ page 251
❑ Long spring pin: is sheared off on removal ⇒ page 252
❑ Long spring pin: installing ⇒ page 252
23 - Planet pinion
❑ Installing ⇒ page 252
24 - Sun wheel
❑ Installing ⇒ page 252

246 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

3.2 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 247
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-

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.

248 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

♦ Press tool -40 - 21-

♦ Thrust plate -40 -

105-

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 21/7-

♦ -4- Counter-support -
Kukko 22/2-
Pressing tapered roller
bearing outer race out of
clutch housing
– First remove mount‐
ing sleeve for flange
shaft oil seal.

3. Differential 249
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

PressingProtected
on tapered roller
by copyright. bearing
Copying inner
for private races purposes, in part or in whole, is not
or commercial
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 same special tools are used for pressing on the tapered roller
bearing inner races for the gearbox housing and the clutch hous‐
ing.

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-

250 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 251
36.0 (long spring pin), No annular groove
removing ⇒ page 252 ,
installing ⇒ page 252

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)

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.
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 251
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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 has a projection

next to the holes -A-.
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.

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

252 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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-.

3.3 Adjusting differential

Special tools and workshop

equipment required
♦ End measuring plate -
VW 385/17-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Universal dial gauge brack‐

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.
et -VW 387-
♦ Press tool -VW 407-
♦ Thrust plate -30 - 205-
♦ Torque wrench -
V.A.G 1331-
♦ -1- Internal puller -Kukko
21/7-
♦ -4- Counter-support -Kukko
22/2-
♦ Dial gauge

3. Differential 253
 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - Edition 02.2011

Procedure
The differential has to be readjusted when the following compo‐
nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearings for differential
Table of adjustments ⇒ page 244
– Press tapered roller bearing outer race without shim into gear‐
box housing using thrust plate -30 - 205- ⇒ page 250 .

Note

The tapered roller bearing inner and outer races are paired. Do
not interchange.

– Press tapered roller bearing outer race into clutch housing

⇒ page 251 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.

254 Rep. gr.39 - Final drive - front differential

 Audi A3 2004 ➤ , Audi A3 Cabriolet 2008 ➤
6-speed manual gearbox 02S - 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.

– 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 outerbyrace
Protected of differential
copyright. tapered
Copying for private roller
or commercial bearing
purposes, in partagain
or in whole, is not
and secure gearbox
permitted housing
unless authorised ⇒ page
by AUDI AG. AUDI 250 . not guarantee or accept any liability
AG does
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Differential 255