Audi Workshop Service and Repair Manuals

Removing gearbox

Special tools and workshop equipment required t  Support bracket -10 - 222 A- t  Hook -10 - 222 A /2- t  Adapters -10 - 222 A /3- t  Adapters -10 - 222 A /8- t  Shackles -10 - 222 A /12- t  Hose clamps, up to 25 mm -3094-

t	Gearbox support -3282-

t	Engine support -3300 A-

t	Support -T10036 A-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Engine and gearbox jack -V.A.G 1383 A-

t  Adjustment plate -3282/32-

t  Socket -V/175-

t  Bits -T10099- Procedure   Note t  Observe the general repair instructions → Chapter. t  Observe rules for cleanliness when working on the gearbox → Chapter. t  Refer to notes on automatic gearbox 09A → Chapter. t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. –  Move selector lever to position „P“.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. gr.27.   Note Before continuing the procedure, the battery earth strap must be disconnected. First check whether a coded radio is fitted and obtain anti-theft coding if necessary. –  With the ignition switched off, disconnect battery earth strap. –  Remove engine cover panel. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove intake hose -1- , connector -2- and hose -3- from air mass meter. –  Remove complete air cleaner housing; to do this, unscrew bolts -4- and -5-. –  Remove intake hose -1-.

–  If fitted, remove bracket -arrow- from gearbox. –  Push selector lever cable -1- off selector shaft lever -4- with screwdriver. –  Do not loosen bolt -2-. –  Remove securing clip -3- at selector lever cable support bracket and tie up selector lever cable.   Note Do not kink selector lever cable.

–  Unplug connector -1- on wiring for multifunction switch -F125-. –  Turn locking lever -2- and unplug connector for gearbox wiring harness. –  Remove electrical connections from starter. –  Remove starter -3- → Electrical system; Rep. gr.27.

–  Clamp off ATF cooler hoses using hose clamps -3094- and detach at ATF cooler. –  Seal off ATF cooler with clean plugs.   Note Seal off open lines and connections with clean plugs or sealing caps to prevent dirt from entering. –  Remove engine/gearbox connecting bolts (top) with bit -T10099/1- (14 mm) or socket/multi-point bit -T10061-. –  Detach fuel line at cylinder head cover. –  If there are hoses and cable connections in area of engine lifting eyes for support bracket -10 - 222 A-, remove these now.

–  Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /3- and adapters -10 - 222 A /8-. –  Partly take up weight of engine/gearbox assembly with the spindles. –  Loosen bolts for left front wheel. –  Raise vehicle. –  Remove left wheel.

–  Detach noise insulation below engine/gearbox -arrows-.

–  Remove left noise insulation -arrows-. –  Detach pressure pipe between charge air cooler and turbocharger from longitudinal member. –  Remove noise insulation (right-side). –  Remove front exhaust system with catalytic converter → Engine, mechanics; Rep. gr.26.

–  Detach earth strap -1- from bracket on gearbox. –  Detach power steering line -2- from front of gearbox -arrows-. –  Detach bracket -3-. –  Then detach power steering line from rear of gearbox (near pendulum support) and tie up to one side. –  Detach bracket from cover of valve body. –  Unbolt drive shafts from gearbox flange shafts. –  Lift drive shaft (right-side) up and secure.

–  Remove engine/gearbox connecting bolt -A- (bottom rear). –  Unclip cap for torque converter nuts. –  Unscrew nuts -arrow- from torque converter (3x) using socket -V/175-. –  To do so, turn crankshaft 120° further each time. –  Detach bracket -B- for wiring of oil level and oil temperature sender -G266- and turn to one side. –  Turn steering to the left.

–  Mark positions of bolts -arrows- securing swivel joint to wishbone (left-side), otherwise wheel alignment will have to be checked. –  Remove bolts -arrows-.

–  Detach coupling rod (left-side) -1- from wishbone and turn coupling rod upwards. –  Swivel wheel bearing housing outwards. –  Guide drive shaft -2- (left-side) out between subframe and gearbox. –  Lift drive shaft and secure to suspension strut with wire.

–  Remove engine/gearbox connecting bolts (bottom) -2- and -3-. –  When doing do, detach bracket -1- for earth strap from gearbox. –  Do not remove connecting bolt -4- at this stage. –  Remove bolts -arrows- and detach pendulum support.

–  Remove hexagon bolts -arrows- for assembly mounting (left-side) -2- from gearbox bracket -1-. –  Carefully tilt engine/gearbox assembly by screwing down both spindles of support bracket -10 - 222 A- approx. 90 mm.

–  Turn flange shaft (right-side) -B- so that flat section is vertical. –  Bolt support -T10036 A- to both securing holes for pendulum support on subframe (bolts -A-). –  Attach engine support -3300 A- so that it is almost touching subframe and secure -arrows-. –  Carefully press engine/gearbox unit forwards.   Note Take care not to damage any of the connecting pipes and hoses when moving the engine/gearbox assembly. Set up gearbox support -3282- to remove 5-speed automatic gearbox 09A with adjustment plate -3282/32-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- as illustrated on adjustment 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 with gearbox.

–  Secure gearbox to gearbox support -3282- with bolt -A-. –  Remove engine/gearbox connecting bolt -arrow-.

–  Push gearbox off engine and at the same time press torque converter out of drive plate. –  Press torque converter against ATF pump -arrow-. –  Carefully pivot gearbox towards subframe.

–  Then lower gearbox carefully, guiding right-hand flange shaft -A- past drive plate and left-hand flange shaft -B- past subframe. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-. –  Secure torque converter to prevent it from falling out.

–  If gearbox is being renewed, transfer gearbox bracket -A--arrows-.