Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 6-cyl. TDI engine

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Support bracket -10 - 222 A-

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

t	Used oil collection and extraction unit -V.A.G 1782-

t	Engine bung set -VAS 6122-

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

t  Adapter -T40058-

t  Gearbox support -T40173-

Preparing gearbox support -T40173-: –  Mounting block attached at -position 1- must be removed. –  Mounting block attached at -position 2- must be rotated so that the longer side faces upwards, as shown in illustration.

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

Vehicles with hydraulic power-assisted steering: –  Extract power steering hydraulic fluid from reservoir -3- with used oil collection and extraction unit -V.A.G 1782-.   Note -Items 1, 2, and 4- can be disregarded.

Continued for all vehicles: –  Remove engine cover panel -arrows-.

–  Remove both front wheels. –  Remove cover -1- for drive shaft from wheel housing (both sides).

–  Remove noise insulation panels -1- and -2- → General body repairs, exterior; Rep. gr.66.

–  Remove front exhaust pipe → Engine, mechanics; Rep. gr.26.

–  Remove bolt -arrow- for ATF lines.

–  Remove particulate filter → Engine, mechanics; Rep. gr.26.

–  Use removal lever -80 - 200- to press ball socket -2- on selector lever cable off gearbox selector lever. –  Pull off retaining clip -1- and move selector lever cable clear.   Note Do not bend or kink the selector lever cable.

Vehicles with in-line ATF filter:   Note Place a cloth below the connection to catch escaping ATF. –  Remove bolts -arrows- and detach ATF line -1- from gearbox.   Note -Items 2 and 3- can be disregarded.   Note

Place a cloth below the connection to catch escaping ATF. –  Remove bolt -1-. –  Pull out retaining clip -arrow- and disconnect ATF line from in-line ATF filter.   Note -Item 2- can be disregarded.

–  Tie up ATF lines -1- and -2-.   Note -Item 3- can be disregarded. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

Vehicles with exchangeable ATF filter:   Note Place a cloth below the connection to catch escaping ATF. –  Remove bolts -arrows-, detach ATF lines -1, 2- from ATF filter housing and tie up. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

Continued for all vehicles: –  Remove bolts -2 … 5- securing gearbox to engine (accessible from above).   Note Item -A- can be disregarded.

–  Set up support bracket -10 - 222 A- with -10 - 222 A /1- on suspension turrets (left and right), as shown in illustration. –  Hook spindle -10 - 222 A /11- onto engine lifting eye (front left). –  Partly take up weight of engine with spindle.

A5 Cabriolet/Sportback: –  Remove diagonal struts (left and right) → Running gear, front-wheel drive and four-wheel drive; Rep. gr.42.

Continued for all vehicles: –  Remove subframe cross brace → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.   Caution Risk of damage to parts of the running gear. Do not let the vehicle down on the wheels if the gearbox mounting, steering box and subframe cross brace are not properly installed.

–  Remove bolts (left and right) -arrows- and detach heat shields -1-.

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Unbolt drive shafts (left and right) from flange shafts on gearbox.

Caution The gearbox control unit (mechatronic unit) can be damaged by electrostatic discharge. t  Before handling the electrical connector, the mechanic must discharge static by briefly touching an earthed metal object, such as vehicle earth, lifting platform or heater radiator, etc. t  Do not touch contact pins in gearbox connector with bare hands. –  Turn fastener anti-clockwise -arrow- and unplug electrical connector on gearbox.

–  Disconnect electrical connector -2- at engine speed sender -G28- and move wiring clear at gearbox.   Note -Item 1- can be disregarded.

–  Detach intermediate steering shaft from steering box and telescope shaft upwards → Rep. gr.48.

–  If fitted, remove bolts -arrows- and detach heat shield -1- for propshaft.

Vehicles with bolted propshaft: –  Remove bolts from connection between propshaft and gearbox (counterhold using counter-hold tool -T10172- with -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to one side.

Vehicles with propshaft with splines on gearbox end:   Note Please refer to the vehicle data sticker or the identification on the rear final drive to find out which type of rear final drive is installed in the vehicle. Then select the appropriate Workshop Manual for the rear final drive. –  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: –  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 for flywheel, counterhold crankshaft with adapter -T40058-.   Note When you then turn the crankshaft, only turn crankshaft in direction of engine rotation -arrow-.

–  Remove 6 bolts -arrow- for flywheel (turn crankshaft 60° in direction of engine rotation each time).

Vehicles with hydraulic power-assisted steering: –  Place used oil collection and extraction unit -V.A.G 1782- below connection. –  Remove bolts -arrows-, detach hydraulic line -1- from steering box and place to one side. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

Continued for all vehicles: –  Remove bolt -1- for starter. –  Detach starter from gearbox but do not remove starter. –  Remove remaining engine/gearbox securing bolts -6 … 10-.   Note Item -A- can be disregarded.

Caution Risk of leaks on ATF oil pan. Do not apply gearbox support -T40173- at ATF oil pan. –  Place gearbox on prepared engine support -T40173-. Gearbox support must be positioned as follows at front of gearbox: l  On left side of gearbox, mounting block -2- engages in opening for flywheel on gearbox housing. l  On right side of gearbox, gearbox support is applied to differential housing. Place flat rubber block -1- between the two to protect housing.

–  Use tensioning strap -1- to secure gearbox.

–  Remove bolts -arrows- for tunnel cross member.   Note The illustration does not show engine and gearbox jack -V.A.G 1383 A-. –  Detach gearbox from engine and lower carefully using engine and gearbox jack -V.A.G 1383 A-.