Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 3.0 ltr. TDI engine

Special tools and workshop equipment required

t	Gearbox support -3282-

t	Adjustment plate -3282/48-

t	Pin -3282/50-

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

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

t	Adapter -T40058-

t  Support bridge -30-211 A- Removing   Note t  General repair instructions → Chapter. t  Rules for cleanliness when working on the automatic gearbox → Chapter. t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. –  Shift selector lever to position “N”.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, disconnect earth wire -arrow- at battery.

–  Carefully detach engine cover panel from the four retaining studs -arrows- one by one.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank. –  Place coolant expansion tank to one side, leaving coolant hoses -1- and -2- connected.

–  Remove heat shield for turbocharger -arrows-.

–  Unscrew engine/gearbox securing bolts -4- and -5- (accessible from above).

–  Remove both front wheels. –  On vehicles fitted with auxiliary heater, remove bolts -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Open quick-release fasteners -1 ... 3- and detach front and rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove noise insulation -1- in wheel housing (left and right).

–  Remove heat shield -1- for drive shaft (left-side). –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Remove nuts -arrows-.

–  Remove bolt -1- at bracket for front exhaust pipe.   Note -Item 2- can be disregarded.   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 clamp -arrow-. –  Detach front exhaust pipe with main catalytic converter.

–  Unbolt heat shield -A- for propshaft -arrows-. –  Unscrew bolts at gearbox/propshaft flange. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie up propshaft to body.   Note

Mark installation position of support bracket for selector lever cable with a felt-tip pen. –  Pry ball socket -1- of selector lever cable off selector shaft lever. –  Unscrew support bracket from gearbox -arrows-. –  Move selector lever cable clear.   Note Shown in illustration with gearbox support removed.

–  Remove engine speed sender -G28- on gearbox -arrow-.

–  Disconnect electrical connector at gearbox by turning fastener cap anti-clockwise -arrow-.   Note

Observe rules for cleanliness when working on automatic gearbox → Chapter. –  Place used oil collection and extraction unit -V.A.G 1782- below engine. –  Disconnect ATF pipes -arrows- at connection points on right side of engine.

–  Unscrew brackets -arrows- for ATF pipes on top section of sump.

–  Disconnect ATF pipes -1- and -2- at connection points on right side of gearbox. –  Take off ATF pipes going to ATF cooler. –  Detach bracket -3- for ATF pipes at bottom of gearbox.

–  Unscrew bolt -arrow-. –  Pull ATF pipes out of gearbox.

–  Unbolt anti-roll bar mountings on both sides -1- and -2-.

–  Disconnect wires -2- and -3- at starter. –  Unscrew bolts -1- and -4- and remove starter. –  Guide out starter towards the rear through wheel housing on right side of vehicle.

–  Remove engine/gearbox securing bolts -3-, -6- and -8 … 10-.   Note Bolt -7- should remain screwed in hand-tight.

–  Insert guide pin of adapter -T40058- so that the large diameter -arrow 1- faces engine. The smaller diameter -arrow 2- faces adapter.

–  Counter-hold crankshaft using adapter -T40058- to slacken torque converter bolts.   Note -Arrow- can be disregarded.

–  Unscrew the 3 torque converter bolts -arrows- through the opening for the removed starter (turning the crankshaft 1/3 turn each time).   WARNING The lock carrier must be installed on the vehicle when performing the following steps.

–  Unscrew nuts -arrows- at stop for torque reaction support. –  Push stop for torque reaction support upwards and tighten nuts again.   Note Adjusting the stop for torque reaction support prevents the engine from tilting at the front after the gearbox is removed.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/48- on gearbox support -3282- as shown in illustration. –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements as illustrated on adjustment plate. –  Note: The pin -3282/50- has to be screwed in at rear right. –  Place engine and gearbox jack -V.A.G 1383 A- with gearbox support -3282- underneath gearbox.   Note The arrow symbol on the adjustment plate points in the direction of travel. –  Align adjustment plate parallel with gearbox.

–  Bolt support to rear left tapped hole on gearbox -1- using one bolt M10x20. –  Insert flattened bolt -3282/50- into mounting hole at rear right of gearbox housing -arrow 2-.   Caution t  The flattened side of the bolt must face towards the gearbox oil pan to prevent the oil pan from being bent or damaged. t  Renew the gearbox oil pan if damaged.

–  Insert bolt into mounting hole at front left of gearbox housing -arrow 2-. –  Insert pin into recess in housing at front right of differential housing -arrow 1-. –  Raise gearbox slightly.

–  Unscrew bolts -arrows- for gearbox mountings (left and right).

–  Remove heat shield for gearbox support (left-side). –  Unbolt gearbox supports (left and right) together with gearbox mountings -arrows-. –  Remove the last engine/gearbox securing bolt. –  Push gearbox off engine and at the same time lever torque converter off drive plate using a screwdriver. –  Carefully lower gearbox using engine and gearbox jack -V.A.G 1383 A-.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  Secure torque converter in gearbox with support bridge -30-211 A- to prevent it dropping out.