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  1. #1
    KB
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    HELP! s3 gearbox refitting!

    Hi all, took out my gearbox this weekend to put in a new clutch, but have spend most of my sunday trying to get the bloodly thing back in! am i missing a trick? has anyone had experance put one of these back in?

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    BASS 666's Avatar
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    have you lined the clutch up propperly ?
    2002 1.9 tdi 130ish brake a4. full reiger body kit, 19 inch rs6 avant rims, eibach springs, home made grill, full leather interior, centre arm rest, quad powerflow exausts, a few engine mods, chrome door mirrors, aero wipers, s line door blades.

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    <tuffty/>'s Avatar
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    Have you removed the transfer box? Quattro boxes really need these to be removed to facilitate refitting (and easier removal for that matter). Does require a special tool to remove the bolt holding the drive shaft flange on...

    I assume you have aligned the clutch plate ok... To make it easier to align the input shaft to the clutch plate I used a 19mm spanner on the end of the crank to turn it round to help it in...

    My efforts here..
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063065

    and here...
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063370

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    KB
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    Yeah the clutch is lined up but im not getting close enough for that to be the issue! the transfer box is in the way! how do i remove it? started to take the tranfer box apart to try and remove it but was a bit scared when i was looking at oily cogs!

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    KB
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    Quote Originally Posted by tufftybloke View Post
    Have you removed the transfer box? Quattro boxes really need these to be removed to facilitate refitting (and easier removal for that matter). Does require a special tool to remove the bolt holding the drive shaft flange on...

    I assume you have aligned the clutch plate ok... To make it easier to align the input shaft to the clutch plate I used a 19mm spanner on the end of the crank to turn it round to help it in...

    My efforts here..
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063065

    and here...
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063370

    <tuffty/>
    Ahhh! thats where i got stuck, i couldnt get the bolt off that holds the drive shaft flange, is it poss without the special tool or is the tool readly available?

  8. #7
    <tuffty/>'s Avatar
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    VAG tool 1669.... looks like this...



    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    KB
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    Thanks tufftybloke, your a star!
    Put billys and h&r springs in this weekend aswell as the clutch, so im dying to get it off the axle stands and have a blast!
    Last edited by KB; 14th November 2010 at 21:09.

  10. #9
    KB
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    Theres actually a lesson to be learned here guys, dont take your s3 into a boggy field to see how good the "4WD" works! i did this and the clutch died! also note the broken rear spring stance!

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    jojo's Avatar
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    Quote Originally Posted by KB View Post
    Theres actually a lesson to be learned here guys, dont take your s3 into a boggy field to see how good the "4WD" works! i did this and the clutch died! also note the broken rear spring stance!
    Haha, love it! Bet you had fun!



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  12. #11
    <tuffty/>'s Avatar
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    Quote Originally Posted by jojo View Post
    Haha, love it! Bet you had fun!
    ...and its still cleaner than yours JoJo lol ;P

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    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  13. #12
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    Quote Originally Posted by tufftybloke View Post
    Have you removed the transfer box? Quattro boxes really need these to be removed to facilitate refitting (and easier removal for that matter). Does require a special tool to remove the bolt holding the drive shaft flange on...

    I assume you have aligned the clutch plate ok... To make it easier to align the input shaft to the clutch plate I used a 19mm spanner on the end of the crank to turn it round to help it in...

    My efforts here..
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063065

    and here...
    http://www.audi-sport.net/vb/a3-s3-f...ml#post1063370

    <tuffty/>
    Hi Tuffty, just looking at your photo of your gearbox and transfer box separated and I have a question. I replaced my gearbox oil this weekend and drained the gearbox and transfer box then refilled, through the gearbox, went for a 2 mile drive then topped up the gearbox . I have no confidence that the transfer box actually filled up from the gearbox whilst driving and looking at this photo it is not clear how the oil would pass from the gearbox into the transfer box. Any ideas or am i driving round with an empty transfer box?
    Paul

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    <tuffty/>'s Avatar
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    Quote Originally Posted by pj123 View Post
    Hi Tuffty, just looking at your photo of your gearbox and transfer box separated and I have a question. I replaced my gearbox oil this weekend and drained the gearbox and transfer box then refilled, through the gearbox, went for a 2 mile drive then topped up the gearbox . I have no confidence that the transfer box actually filled up from the gearbox whilst driving and looking at this photo it is not clear how the oil would pass from the gearbox into the transfer box. Any ideas or am i driving round with an empty transfer box?
    Paul
    Its all fine mate... there are holes in the transfer box that allow oil through from the gearbox... I thought the same until I actually removed the transfer/bevel box and saw for myself...



    See the two smaller green oil seals... thats where the oil goes through..

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    That clears that up then, thanks. I assume th lower hole allows oil through and the top hole allows air back to the gearbox. Hopefully you dont mind if I add this photo to another thread...

  16. #15
    <tuffty/>'s Avatar
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    Sure, why not

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    Hi guys, I have a quick question:

    I recently changed my gearbox oil on my s3 ( actually my mate did - I supervised!) All we did was remove the drain plug then re fitted, got the car level on jacks, then refilled through the fill plug untill it dribbled out. This talk of driving for a couple of miles to fill the transfer box has me a little concerned - I diddn't check the level again. Should I have? The volume of oil out was roughly the same as what went in. Am I being paronoid?

    Cheers,

    Colin

  18. #17
    <tuffty/>'s Avatar
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    Quote Originally Posted by colinra View Post
    Hi guys, I have a quick question:

    I recently changed my gearbox oil on my s3 ( actually my mate did - I supervised!) All we did was remove the drain plug then re fitted, got the car level on jacks, then refilled through the fill plug untill it dribbled out. This talk of driving for a couple of miles to fill the transfer box has me a little concerned - I diddn't check the level again. Should I have? The volume of oil out was roughly the same as what went in. Am I being paronoid?

    Cheers,

    Colin
    Did you drain from the transfer box too? there is another plug on the transfer box too that would have helped get the last of the old oil out as a little will have collected in the transfer box...

    You should be ok but I would definitely check the level again to be sure... I did...

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    Cheers tuffty, I didn't touch the transfer box drain plug, only the gearbox plug, so it should be OK. I will check the level again to be safe.

    Thanks for the response.

    Colin

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    Quote Originally Posted by KB View Post
    Ahhh! thats where i got stuck, i couldnt get the bolt off that holds the drive shaft flange, is it poss without the special tool or is the tool readly available?
    Doe s removing the driveshaft flange plate result in oil loss.
    Cheers

  21. #20
    jojo's Avatar
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    Quote Originally Posted by purple8 View Post
    Doe s removing the driveshaft flange plate result in oil loss.
    Cheers
    No.



    99' Audi S3(APY) - Brilliant Black Click>>>Going Sideways vid!
    You've got to have a laugh! For Sale:LCR Brakes - £400



  22. #21
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    Quote Originally Posted by jojo View Post
    No.
    It blooming well does on an asv engine when you jiggle the box about to get it to pop in. I know have nice pool of box oil lol

 

 

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