Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with V6 engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Hose clamps, up to 25 mm -3094-

t	Gearbox support -3282-

t	Adapter -VW 771/40-

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

t  Removal lever -80 - 200- for vehicles from 06.2008 onwards

t  Pin -3282/29-

t  Adjustment plate -3282/33-

t  Stepladder -VAS 5085- t  Grease for clutch plate splines -G 000 100- t  Grease -G 000 450 02- t  Universal grease -G 052 735- t  Bolt M10x20

Procedure   Note Re-attach all cable ties at the same locations when re-installing.   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  With ignition switched off, disconnect battery earth wire -arrow- → Electrical system; Rep. Gr.27. –  Remove engine cover panel.

–  Remove air cleaner housing completely → Rep. Gr.24.

–  Detach line -1- from air cleaner bracket -2-. –  Remove bolts -arrows- and remove air cleaner bracket.

Metal gate relay lever: –  Detach securing clips -1- and -2- on both cables. –  Detach cable end-pieces with selector cables from gearbox selector lever and gate relay lever.

Plastic gate relay lever: l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing relay lever. –  Pull locking mechanism forwards in direction of -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock. –  Then press gate relay lever forwards (in direction of -arrow 3-). l  Detach cable end-piece only when gate relay lever is removed → Fig..

Continued for all vehicles: –  Detach cable support bracket from gearbox -arrows-; then move to one side and tie up together with selector cables.

–  Unscrew earth wire -1- from upper starter bolt.   Note Connector -2- and wire -3- remain in position on starter.

–  If a plastic pipe is installed between clutch master cylinder and slave cylinder, clamp off supply hose to clutch master cylinder using hose clamp up to 25 mm -3094-.

–  If a pipe/hose assembly is installed between clutch master cylinder and slave cylinder, clamp off hose -A- using hose clamp -3094-.   Note -Arrow- can be disregarded.   Note

t  In the following steps make sure that no brake fluid escapes onto the starter or onto the gearbox below. If this does happen, clean the affected area thoroughly. t  Place a cloth underneath to catch escaping brake fluid. –  Release clip -3- with a screwdriver and disconnect pipe/hose assembly -1- or plastic pipe from connection -4-. –  Detach pipe/hose assembly from bracket and move clear to the side.   Note -Item 2- can be disregarded.   Caution Do not operate clutch pedal after disconnecting pressure line from slave cylinder.

–  Unscrew top engine/gearbox securing bolts -arrows-. –  Then remove upper securing bolt from starter.

Vehicles from 06.2008 onwards: –  Lever clip off sealing element using removal lever -80 - 200- and fold up sealing element.

Continued for all vehicles: –  Fit support bracket -10-222A- together with racks -10 - 222 A /1- and adapters -10-222A/3- onto wing mounting flanges. –  Hook adapter -10 - 222 A /20- into lifting eye on right side of engine. –  Take up weight of engine evenly with both spindles; do not lift.

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

–  Remove noise insulation (left-side) -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-.

–  Unplug electrical connector -2- for reversing light switch -F4-. –  Remove nut -1- and detach bracket from bottom starter bolt with electrical wiring. –  Unscrew bottom bolt securing starter -1-. –  Place starter to side onto longitudinal member.

–  Remove exhaust system bracket from subframe -arrows-.

–  Disconnect exhaust system at clamp -arrows-. –  Tie up the front exhaust pipe.   Note To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.

–  If fitted, remove front left vehicle level sender -G78--arrows-.

–  Detach connector -1- from oil level and oil temperature sender -G266-.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unbolt propshaft with flexible coupling from bevel box -arrows- (counterhold triangular flange with suitable lever).

–  Remove bolts -2- and -3- for pendulum support on gearbox.   Note

Slackening off securing bolts for pendulum support causes engine/gearbox assembly to swing forwards slightly (towards front end). Make sure that the seal -arrow- in the flange of the propshaft is not damaged when removing and installing. –  Push engine/gearbox assembly forward slightly (towards front end) and then pull propshaft off bevel box. –  Lift propshaft up and secure with wire. –  Unscrew coupling rods on left and right of anti-roll bar.

–  Unscrew nuts -arrows- securing swivel joint to wishbone. –  Detach steering box from subframe and tie it up. –  Before removal, fix subframe in position → Rep. Gr.40. –  Remove subframe with anti-roll bar, suspension brackets and wishbones → Rep. Gr.40.

–  Unbolt heat shield for drive shaft (right-side) from bevel box -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts. –  Lift drive shafts as high as possible and secure with wire, making sure you do not damage surface coating.

–  Unscrew bolts -arrows- for gearbox carrier on bevel box and engine. –  Remove gearbox carrier.

–  Remove bolt -arrow- from above bevel box.

–  Remove bolts -arrows- on gearbox mounting.

–  By adjusting spindles on support bracket -10 - 222 A-, lower gearbox by distance -a-. l  Dimension -a- = 70 mm.

–  Unbolt gearbox support from gearbox -arrows-.

Metal gate relay lever: –  Pull securing clip -arrow- off gate relay lever -1- and remove gate relay lever.

Plastic gate relay lever: –  Press in detent -arrow 1- as far as stop and remove gate relay lever together with cable end-piece (move relay lever in normal direction of operation).   Note -Item 2- can be disregarded.

Continued for all vehicles: –  Remove engine/gearbox connecting bolt -arrow- (on engine side).

–  Unscrew engine/gearbox securing bolt -arrow- located next to bevel box -C-.   Note Note: retaining clip -A- securing bolt -arrow- is fitted in sump -B-.

To remove gearbox “02Q” set up gearbox support -3282- with adjustment plate -3282/33-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate. –  Bolt on support elements -A-, as illustrated on adjustment plate. –  Screw in pin -3282/29- instead of support element-C-. –  Place engine and gearbox jack under vehicle; arrow symbol -B- on adjustment plate points to front of vehicle. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox.

–  Secure adapter -VW 771/40- in tapped hole of gearbox housing, as shown in illustration. –  Secure gearbox to gearbox support -3282- with bolt M10x20 -A-.

–  Unscrew last engine/gearbox securing bolts at bottom -1 ... 3-. –  Press gearbox off engine (dowel sleeves). –  Carefully lower gearbox.   Note When lowering gearbox make sure the electromechanical power steering is not damaged.