Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 3.0 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Spindle -10 - 222 A /11-

t	Ring spanner insert, 16 mm -V.A.G 1332/14-

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

t	Stepladder -VAS 5085-

t	Puller -T40160-

t	Gearbox support -T40173-

t  Counterhold tool -T10172- with adapters -T10172/5-

t  Adapter -T40058-

t  Release tool -T40138-

t  Extractor -T40176-

Removing   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Bring wheels into straight-ahead position. –  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal → Rep. gr.27.

–  Remove engine cover panel -arrows-. –  Remove both front wheels.

–  Detach noise insulation -1- from wheel housing (both sides).

–  Loosen fasteners -1 … 3- and remove noise insulation panels.

–  Remove front exhaust pipe and particulate filter → Rep. gr.26.

–  Working from above, remove bolt -3- for connecting rod.   Note -Items 1 and 2- can be disregarded.

–  Remove bolts -2 … 6- securing gearbox to engine (accessible from above).

–  Set up support bracket -10 - 222 A- with rack -10-222 A /1- and spindle -10 - 222 A /11- as shown in illustration.

–  If fitted, remove bolts -arrows- and detach heat shield -A- for propshaft.

Propshaft with bolted connection at gearbox end: –  Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool -T10172- with adapters -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to one side. Propshaft with splined connection at gearbox end: –  Remove propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39.

Continued for all vehicles: –  Remove bolt -1- for hydraulic fluid pressure line for power steering.   Caution Risk of damage to parts of the running gear. Do NOT let the vehicle down on the wheels if the subframe, steering box or subframe cross brace are not properly installed. Do NOT support the vehicle at the subframe or the subframe cross brace (e.g. with a trolley jack). –  Remove bolts -arrows- and detach subframe cross brace.

–  If fitted, remove subframe shield -1- (left and right); to do so, unscrew bolts -arrows- and take out shield towards inside.

–  Remove bolt -2- and tie up clutch slave cylinder to side in engine compartment.   Caution Risk of damage to clutch slave cylinder. Do not depress clutch pedal after removing slave cylinder. –  Remove nut -1-.

Caution Risk of damage to selector shaft in gearbox. Do not prise off or knock off the gearbox selector lever -1- with a lever or hammer. –  Apply puller -T40160- and pull off gearbox selector lever -1-.

Caution Risk of damage to coil connector for airbag. t  Front wheels must be in straight-ahead position when universal joint is detached from steering box. t  Do not change position of steering wheel or steering box after this step (if necessary, fix steering wheel in position with adhesive tape). –  Remove bolt -arrow- for universal joint → Rep. gr.48. –  Press universal joint off steering box and push all the way up.

–  Pull cover -1- off bottom of gearbox -arrow-.

–  Insert guide stud of adapter -T40058- as follows: l  The larger diameter -arrow 1- faces engine. l  The smaller diameter -arrow 2- faces adapter.

–  To slacken bolts securing clutch module to drive plate, counterhold crankshaft with adapter -T40058- at vibration damper.   Note -Arrow- can be disregarded.

–  Remove 6 bolts -arrow- securing clutch module to drive plate (turn crankshaft 60° in direction of engine rotation each time).

–  Remove bolt -1- for starter from engine side. –  Detach starter from gearbox but do not remove starter. –  Remove remaining engine/gearbox securing bolts -7 … 11-.

–  Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- underneath gearbox and secure with tensioning strap -1- as shown in illustration.

–  Remove bolts -arrows- for tunnel cross member.

–  Lower gearbox initially only by dimension -a- using engine and gearbox jack -V.A.G 1383 A-. l  Dimension -a- = 70 mm (maximum)

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).   Note The installation position is shown with the gearbox removed. –  Unbolt drive shafts (left and right) from flange shafts on gearbox.

–  Disconnect electrical connector -1- for gear detector switch -F208- using release tool -T40138- and move wiring clear. –  Remove bolt -2- for push rod.   Note -Item 3- can be disregarded.

–  Partly take up weight of engine with spindle -10 - 222 A /11-.   Note Use stepladder -VAS 5085- for access to spindle -10 - 222 A /11- while vehicle is raised. –  Detach gearbox from engine and lower carefully using engine and gearbox jack -V.A.G 1383 A-.