Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 8-cyl. FSI engine (Audi RS 4)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

t	Locating pins -3393-

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

t	Wing compensation plates -T40045-

t	Drill Ø 10.2 mm

t	Bolt M10x20 (2x)

t	Copper grease -Z 381 351 TE-

t	Grease for clutch plate splines -G 000 100-

Removing   Note t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. t  Heat insulation sleeves and heat shields removed during removal of gearbox must be fitted in the same positions when installing.

–  Lift up floor covering in boot and secure in position.   Caution Follow steps required when disconnecting battery → Rep. Gr.27. –  With ignition switched off, disconnect battery earth strap -arrow-.

–  Detach bonnet seal at lock carrier and at wing flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

–  Set up support bracket -10-222 A- on wing mounting flanges. –  Attach two spindles to lifting eyes at rear of engine. –  Partly take up weight of engine on spindles of support bracket, but do not lift.

–  Remove both front wheels. –  Release quick-release fasteners -1-, unscrew bolts -2- and remove noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Unbolt bracket for wiring harness at engine support (right-side) -arrows-.

–  Unscrew nuts -1- at bottom of engine mountings (left and right).

–  Detach electrical connector -2- from vehicle level sender (front left) -G78-.   Note -Item 1- can be disregarded.

–  Before slackening subframe mountings, check whether locating pins -3393- can be fully inserted into holes -1- and -2- in subframe -arrow-.   Caution If this is not the case, wheel alignment has to be performed after installing the subframe.

–  First remove front bolts -2- and -3- on subframe (left and right). Then remove bolts -1-. –  Lower subframe at the front.

–  Unscrew bottom engine/gearbox securing bolts -arrows-.

–  Temporarily secure subframe again. Temporary tightening torque: 1 -  110 Nm 2 -  75 Nm 3 -  75 Nm   WARNING Do not renew bolts yet or tighten to their final torque. This will be done when installing the gearbox.   Note

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Disconnect exhaust system at clamps -1- and -2-.

Caution Risk of damage to engine speed sender -G28-. t  Remove engine speed sender -G28- before removing gearbox. t  Otherwise the engine speed sender -G28- will be damaged irreparably when the gearbox is pulled off the engine. –  Bend heat shield slightly to one side. –  Unscrew bolt -arrow- at engine speed sender -G28- on left side of gearbox. –  Move engine speed sender -G28- with heat shield clear to one side.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to rear cross member from below (place a block of wood -arrow- between lifting column and cross member). –  Support rear cross member with engine and gearbox jack -V.A.G 1383 A-. –  First unscrew bolts -1- and -2-, then bolts -3- and -4-.

–  Lower rear cross member slowly with engine and gearbox jack -V.A.G 1383 A- until distance between rear cross member and body reaches dimension -x-. l  Dimension -x- = 60 mm (maximum)   Note The gearbox must not be lowered further than this, otherwise the propshaft joint and wiring or other connections at the bulkhead can be damaged. If necessary re-adjust spindles of support bracket -10-222 A- so that dimension -x- is not exceeded.

–  Unbolt heat shields -arrow- for drive shafts (left and right). –  Unbolt drive shafts from gearbox flanges.   Note Make sure you do not damage surface coating on drive shafts.

–  Detach electrical connectors -1 ... 4- from bracket on gearbox. –  Unplug electrical connectors. –  Detach heat insulation sleeve at wiring harness and move individual lengths of wiring clear.

–  Remove bolts -1- and -2- and remove bracket for front exhaust pipe (left side).

–  Remove nuts -arrows-. –  Detach front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter.

–  Unbolt bracket for front exhaust pipe (left-side) on gearbox -arrows-.

–  Unscrew bolts -1- and -2- and remove front exhaust pipe bracket (right-side).

–  Remove nuts -arrows-. –  Detach front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter.

–  Unbolt bracket for front exhaust pipe (right-side) on gearbox -arrows-.

–  Unscrew two nuts -arrows- and detach tunnel cross member.

–  Unbolt heat shield for propshaft -arrows-.

–  Remove bolts -arrows- at gearbox/propshaft flange. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie up propshaft to side.

–  Unplug electrical connector -arrow- for reversing light switch -F4- on gearbox (right-side). –  Move electrical wiring clear.

–  Unscrew connecting rod -2- for selector rod. –  Remove hexagon socket head bolt from push rod -1-.

–  Unscrew nut -arrow- and detach gearbox selector lever from selector shaft. –  Move wiring for Lambda probes clear at top of gearbox.

–  Remove bolts -2- and -4- on heat shield for starter. –  Remove retaining nut -3- and bolt -1-. –  Pull starter out of gearbox bellhousing. –  Remove remaining engine gearbox securing bolts, but leave 2 bolts in position (tightened lightly).

–  Drill a hole of 10.2 mm Ø -arrow- in supporting element of gearbox support -3282-.

–  To remove manual gearbox 0A3, four-wheel drive, set up gearbox support -3282- with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The positions of the support elements -arrows- are shown on the adjustment plate in schematic form (the arrow points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Align the adjustment plate parallel to the gearbox. –  Secure the supporting elements to the left side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on right side- to 20 Nm.

–  Secure the supporting elements to the right side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on left side- to 20 Nm. –  Remove 2 last engine/gearbox bolts. –  Press gearbox off dowel sleeves and lower carefully with engine and gearbox jack -V.A.G 1383 A- just far enough to gain access to the clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic line to clutch slave cylinder is not damaged.

–  Detach clutch slave cylinder -arrow-; do not open hydraulic connections. –  Lift clutch slave cylinder clear and tie up together with selector linkage.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If you will be installing a new gearbox instead of the one removed, the gearbox mounting has to be transferred to the new gearbox -arrows-.