Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with V6 petrol engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Lifting tackle -2024 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/12-

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

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

t  Wing compensation plates -T40045-

Procedure   Caution Follow steps required when disconnecting battery → Rep. Gr.27. –  Detach rubber seal of plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- to front. –  With ignition switched off, disconnect earth wire at battery → Rep. Gr.27.

–  Pull off rear engine cover panel -arrows-.

–  Pull off front engine cover -arrows-.

–  Remove cover -1- on left side of engine compartment.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical wiring leading to coolant shortage indicator switch -F66- at expansion tank (bottom) and tie expansion tank clear to one side (with coolant hoses -1...3- attached).

–  Remove cover -1- on right side of engine compartment.

–  Remove bolts -arrows- from solenoid valve mounting plate -3-. –  Detach crankcase breather hose -4- from air duct -2-.

–  Unscrew bolt -arrow- and disconnect air duct -2- from throttle valve module -J338-. –  If fitted, detach hose -1- from air duct.   Note For illustration purposes, the air duct is shown from rear, with engine removed. –  Unscrew engine/gearbox securing bolts which are accessible from above.

–  If fitted, remove heat shield for connectors from left of bulkhead. –  Detach electrical connectors -1 ... 4- from retainer at left of bulkhead. –  Unplug electrical connectors -1- and -4-.

–  Detach electrical connectors -1 ... 4- from retainer at right of bulkhead. –  Unplug electrical connectors -1- and -4-. –  Move Lambda probe wires on left and right clear. –  Remove retainer for connectors on left and right.

–  Unscrew nut -2- (accessible from above), connecting front exhaust pipe to exhaust manifold on left side.   Note t  For illustration purposes here shown with engine removed. t  The nuts -1- and -3- (accessible from below) are removed at a later stage.

–  Unscrew nut -2- (accessible from above), connecting front exhaust pipe to exhaust manifold on right side.   Note t  For illustration purposes here shown with engine removed. t  The nuts -1- and -3- (accessible from below) are removed at a later stage.

–  Pull off bonnet seal at both wing mounting 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.

–  Remove eye of lifting tackle -2024 A-. –  Re-insert pin -1- in centre hole of lifting tackle and secure with split pin. –  Hook pin on lifting tackle -2024 A- onto spindle of support bracket -10-222 A-. –  Hook lifting tackle -2024 A- into lifting eyes at front and rear of engine.   WARNING The hook attachments and locating pins on the lifting tackle must be secured with locking pins -arrows-. –  Take up some of the engine weight by tightening spindle of support bracket, but do not lift.

–  On vehicles fitted with auxiliary heater, remove screws -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Remove noise insulation panel -arrows-.

–  Unbolt bracket for noise insulation -arrow-.

–  Unscrew heat shield -arrows- for drive shaft (left and right). –  Unbolt drive shafts -1- (left and right) from gearbox flange shafts.   Note Make sure you do not damage surface coating on drive shafts.

–  Unscrew bolts -1 ... 4- and remove front cross piece, if fitted.   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 -arrows-.

–  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold on left side.   Note For illustration purposes here shown with engine removed.

–  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold on right side.   Note For illustration purposes here shown with engine removed. –  Detach front exhaust pipe from exhaust manifold on left and right sides. –  Detach front section of exhaust system on left and right sides. –  Disengage rear section of exhaust system at rubber mountings and remove.   Note A second mechanic is required for removing the rear section of the exhaust system.

–  Unbolt heat shield for propshaft -arrows-.

–  Unbolt propshaft from gearbox. –  To do this, use counterhold tool -T10172- with adapter -T10172/5- –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.

–  Use wire -arrow- to tie propshaft -1- onto heat shield.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to gearbox from below (place a block of wood -arrow- between lifting column and gearbox) and support gearbox.

–  First remove bolts -1- and then bolts -2- at rear cross member. –  Unscrew two nuts -3- and detach rear cross member.

–  Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox up slightly.

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

–  Unbolt starter -1--arrows- and pull it away from bell housing. –  Remove remaining engine gearbox securing bolts, but leave one bolts in position (tightened lightly).

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

–  If fitted, unplug electrical connector -arrow- for speedometer sender -G22- on left of gearbox.

–  If fitted, unbolt head shield for engine speed sender -G28- from gearbox and remove bolt -arrow-. –  Remove engine speed sender -G28- and move clear.

–  Unscrew connecting rod -2- for selector rod. –  Detach push rod -1-; to do so, unscrew hexagon socket head bolt.

–  Unscrew nut -1- and detach selector shaft lever -2- from gearbox selector shaft.

–  To remove manual gearbox 01E (four-wheel drive) set up gearbox support -3282- with adjustment plate -3282/12- and place on engine and gearbox jack -V.A.G 1383 A-. –  Fit support elements -A-.   Note

t  The positions of the support elements are shown on the adjustment plate -3282/12- in schematic form -A- (the arrow -B- points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Place engine and gearbox jack -1383 A- with gearbox support -3282- underneath gearbox and position adjustment plate so it is parallel with gearbox.

–  Secure support elements -arrow- to left and right side of gearbox. –  Remove the remaining engine/gearbox securing bolt. –  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 pipe/hose to slave cylinder is not damaged.

–  Remove clutch slave cylinder -arrow- and tie up with wire. Do not disconnect hoses/pipes.   Caution t  Do not depress clutch pedal after removing clutch slave cylinder. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely with engine and gearbox jack -V.A.G 1383 A-.   Note t  Make sure that all wiring has been detached from top of gearbox. t  When lowering gearbox make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being renewed, the gearbox mounting -1- must be transferred to the replacement gearbox -bolts 2-.