Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 6-cylinder engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/43-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

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

t  Lifting tackle -2024 A- t  Grease for clutch plate splines -G 000 100- t  Copper grease (commercially available) Procedure   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 removed during removal of gearbox must be fitted in the same position when installing.   Caution Follow steps required when disconnecting battery → Rep. Gr.27.

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

Vehicles with 6-cylinder 2.4 ltr. engine: –  Remove engine cover panel -arrows-.

Vehicles with 6-cylinder 3.0 ltr. engine: –  Pull off rear engine cover -arrows-.

–  Pull off front engine cover -arrows-.

Continued for all vehicles: –  Remove cover -1- on left side of engine compartment.

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

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

–  Remove bolts -arrows- from solenoid valve mounting plate -3-. –  Detach air intake hose -1- from air-mass meter. –  Pull hose -4- for crankcase breather system off 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 In the illustration, the air duct is shown from the rear and with the engine removed. –  Unscrew engine/gearbox securing bolts which are accessible from above.

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

–  Unscrew nut -2- (access from above), connecting left front exhaust pipe with exhaust manifold.   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.

–  Detach rubber seal from edges of 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 middle hole on lifting tackle and secure it with split pin. –  Hook pin on lifting tackle -2024 A- onto spindle on support bracket -10-222 A-. –  Hook lifting tackle -2024 A- into lifting eyes at front and rear of engine.   WARNING Support hooks and locking pins on lifting tackle must be secured with retainers -arrows- in illustration. –  Slightly pretension engine with spindle of support bracket.

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

–  Loosen bolts/quick-release fasteners -1- and -2- and remove front noise insulation -A-. –  If fitted, loosen quick-release fasteners -3- and remove rear noise insulation -B-.

–  Detach bracket -arrow- for noise insulation.

–  Remove heat shield -arrow- for drive shafts (left and right).

–  If fitted, remove tunnel cross member (front) -1 ... 4-.

–  Disconnect exhaust system at clamps -arrows-. –  Remove front exhaust pipe (left-side) with catalytic converter → Rep. Gr.26. –  Remove bracket for exhaust pipe (front right) from gearbox.

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

–  If fitted, unclip operating rod for vehicle level sender -G78- from lower transverse link -arrow-.

–  Before loosening the subframe, use locating pins -3393- to check whether holes -1- and -2- are aligned. 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 -  approx. 100 Nm 2 -  approx. 70 Nm 3 -  approx. 70 Nm   Caution Do not renew bolts yet or tighten to their final torque. This will be done when installing the gearbox.

–  Remove drive shafts -1- from flange shafts and tie up to side.   Note Make sure you do not damage surface coating on drive shafts. –  Support gearbox with engine and gearbox jack -V.A.G 1383 A-. –  First remove bolts -2- and then bolts -3- at tunnel cross member. –  Unscrew the two nuts -4- and detach tunnel cross member. –  Carefully lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

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

–  Detach connector -arrow- for reversing light switch -F4- at right side of gearbox.

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

–  Open cable ties -arrows A and B-, unclip Lambda probe wiring at side -arrows C- and move wiring clear.

–  Unbolt starter from engine/gearbox and secure as necessary → Rep. Gr.27.   Note Starter cables do not have to be disconnected.

–  If fitted, remove engine speed sender -G28- from left side of gearbox -arrow- and lay aside.

–  Unscrew upper engine/gearbox securing bolts as well as those on the side, except for bolts marked with -arrow A- and -arrow B-.

–  Drill a hole of 10.2 mm Ø -arrow- in the support elements of gearbox support -3282-.

–  To remove manual gearbox 01X, set up gearbox support -3282- with adjustment plate -3282 /43- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The support elements-arrows A- and -arrows B- are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points in the direction of travel. t  Adjustment plate can only be fitted in one correct position.

–  Align the adjustment plate parallel to the gearbox. –  Secure support elements to left side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on right side- to 20 Nm.

–  Secure support elements to right side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on left side- to 20 Nm.

–  Remove remaining engine/gearbox securing bolts -arrow A- and -arrow B-. –  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 clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic pipe/hose to slave cylinder is not damaged.

–  Remove clutch slave cylinder from gearbox -arrow- and secure with wire, do not open pipe/hose system.   Caution Do not depress clutch pedal after removing clutch slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts. –  Before carrying out assembly work, secure gearbox to assembly stand, using engine and gearbox support -VW 540- → Chapter.

–  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- → Anchor. Installing gearbox → Chapter