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Gearbox Swap Q's

Discussion in 'A4/S4 forum(B5 Chassis)' started by Rallyman, Sep 4, 2009.

  1. Rallyman
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    Rallyman LPG Abuser & have VAGCOM

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    A little while ago I was searching for a replacement box for my 1.8 QTS.
    Well I managed to find one with the help of a couple of people.... thanks guys.
    I am attempting this tomorrow, Toools, new clutch ready (OUCH £500 - inc DMF) and lots of Tea n biscuits ready.....<praying for nice weather!>
    How much oil does my Q'box need and what type (ie 75-90w). The stealers didnt have any and niether did halfrauds...... Any help?
    Cheers
    Michael
    P.s. if anyone has done this job before and knows of any help that they can pass on - I'd be very greatful for it - thanks
    Last edited: Sep 4, 2009
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  2. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    2.75 litres of Gear oil G 052 911 A SAE 75 W 90 (synthetic oil)
    Stolen direct from ELSAWiN

    The job isnt too hard, but the box is quite heavy when you are trying to push it tno position on your own laying on your back
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  3. Rallyman
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    Rallyman LPG Abuser & have VAGCOM

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    Thank for that, Halfords said 2.75 and Audi said 6 litres!
    Ive just spent the last hour or so sorting out elsawin.
    Im having a look a the propshft alignment, how much of an issue is it - there is a spcial tool to sort it, any tips?
    I have a willing volanteer :p to help me we have plenty of experience of RWD gearbox changes (though not as heavy!)
    Oh will I need to get that new propshaft gasket thingey?
    Cheers
    Michael
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  4. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator

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    Nah, no oil will leak out as the rear prop bolts to a flange (ooh er mrs)

    Make a note that the front shafts are bolted on by spline bolts and not torx, and the rear ones can be removed with a bi hex 10mm combi spanner
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  5. Rallyman
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    Rallyman LPG Abuser & have VAGCOM

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    I'll get some pics as I do it.... (ooer missus) the gearbox that is.....
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  6. Rallyman
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    Rallyman LPG Abuser & have VAGCOM

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    Achey arms, sore and cut back ..... I ve done it..... woohoo..... no pictures sorry..... original box (shafted 4th syncro) & clutch down to rivets.... Spent about day and a half on it. took our time, getting it perfect... :) gotta buy some more bits like a new LH g.box mount and seals
    Brand new clutch and Dual Mass Flywheel... (£500) GSF....OUCH!
    Wow! took it for a quick spin tonight.........silky smooth clutch peddle ( it was so light I thought that there was something wrong!)....
    Well worth the weekend :)
    If you're thinking of doing a clutch swap (or gearbox) on your quattro, here is what you need:
    2 people with a weekend (nice weather) plenty of Tea and biscuits,
    Good socket set and 16mm spanners, and lots of extensions
    Multi spline drive sockets
    6x new Flywheel to Crankshaft bolts
    Gearbox mounts - good idea to check LH side
    3x New Cork gaskets for prop and drive shafts - Audi £6.49 each
    Trolley jacks
    Elsawin (REALLY helps)
    and some magic in a can (WD40)
    baths (I managed to remove over a 1kg of mud from the car doing this job!)
    Thanks guys who contributed to me finding a new box.....
    Thanks Chris for helping me he's so magic with cars he can do this......hahhha!
    [​IMG]

    Cheers
    Michael
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