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HELP! s3 gearbox refitting!

Discussion in 'A3/S3 Forum (8L Chassis)' started by KB, Nov 14, 2010.

  1. KB
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    KB Member

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    [Nov 14, 2010]
    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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  3. BASS 666
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    BASS 666 BMW aye right dead on..

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    [Nov 14, 2010]
    have you lined the clutch up propperly ?
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  4. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Nov 14, 2010]
    Have you removed the xfer box? Thats my advice if not
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  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 14, 2010]
    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-...s-s3-minor-modding-thread-16.html#post1063065

    and here...
    http://www.audi-sport.net/vb/a3-s3-...s-s3-minor-modding-thread-17.html#post1063370

    <tuffty/>
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  6. KB
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    KB Member

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    [Nov 14, 2010]
    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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  7. KB
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    KB Member

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    [Nov 14, 2010]
    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?
    #6
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 14, 2010]
    VAG tool 1669.... looks like this...

    [​IMG]

    <tuffty/>
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  9. KB
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    KB Member

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    [Nov 14, 2010]
    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!:laugh:
    Last edited: Nov 14, 2010
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  10. KB
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    KB Member

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    [Nov 14, 2010]
    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![​IMG]
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  11. jojo
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    jojo Looking for Boost! Staff Member Moderator

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    [Nov 15, 2010]
    Haha, love it! Bet you had fun!
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  12. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 15, 2010]
    ...and its still cleaner than yours JoJo lol ;P

    <tuffty/>
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  13. pj123
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    [Nov 15, 2010]
    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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  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 15, 2010]
    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...

    [​IMG]

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

    <tuffty/>
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  15. pj123
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    pj123 Member

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    [Nov 15, 2010]
    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...
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  16. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 15, 2010]
    Sure, why not :)

    <tuffty/>
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  17. colinra
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    colinra Member VCDS Map User

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    [Nov 15, 2010]
    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
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  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Nov 15, 2010]
    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/>
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  19. colinra
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    colinra Member VCDS Map User

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    [Nov 16, 2010]
    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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  20. purple8
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    [Oct 20, 2012]
    Doe s removing the driveshaft flange plate result in oil loss.
    Cheers
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  21. jojo
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    jojo Looking for Boost! Staff Member Moderator

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    [Oct 20, 2012]
    No.
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  22. purple8
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    purple8 Member

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    [Oct 22, 2012]
    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
    #21

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