Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 8-cyl. MPI engine (Audi S4)

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Shackle -10-222 A /12-

t	Lifting tackle -2024 A-

t	Hose clamps, up to Ø 25 mm -3094-

t	Gearbox support -3282-

t	Adjustment plate -3282/38-

t  Locating pins -3393-

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

t  Wing compensation plates -T40045- t  Drill Ø 10.2 mm t  Bolt M10x20 (2x) t  Grease for clutch plate splines -G 000 100- t  Copper grease -Z 381 351 TE- Removing   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 → Electrical system; Rep. Gr.27.

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

–  Pull off rear engine cover -arrows-.

–  Pull off front engine cover -arrows-.

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

–  Clamp off coolant hose -1- with hose clamps -3094- and pull hose off coolant expansion tank. –  Unbolt coolant expansion tank -2--arrows-. –  Unplug electrical wire leading to coolant shortage indicator switch -F66- at expansion tank (bottom) and move coolant expansion tank (with coolant hose -3- attached) clear to one side. –  If necessary, close off the connection with a suitable plug.

–  Detach electrical connectors -1 ... 4- from retainer at left of bulkhead. –  Unplug electrical connectors -1-, -3- and -4-. –  Detach retainer at bulkhead. –  Detach heat insulation sleeve at wiring harness and move wiring harness clear. –  Move Lambda probe wires clear (downwards).

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

–  Remove air intake hose -arrows-.

–  Detach connectors -1 ... 4- from retainer at right side of bulkhead. –  Unplug electrical connectors -2- and -4-. –  Move Lambda probe wires clear (downwards).

–  Fix a shackle -10-222 A /12- to engine lifting eye (rear right).   Note -Item 1- can be disregarded.

–  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 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 eye at front of engine and into shackle -10-222 A /12- at rear.   WARNING The hook attachments and locating pins on the lifting tackle must be secured with locking pins -arrows-. –  Partly take up weight of engine on spindle of support bracket, but do not lift.

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

–  Release quick-release fasteners -1-, unscrew bolts -2- and remove noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Unbolt bracket for wiring harness at engine support (right-side) -arrows-.

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

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

–  Before slackening subframe mountings, check whether locating pins -3393- can be fully inserted into holes -1- and -2- in subframe -arrow-.   Caution 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 -  110 Nm 2 -  75 Nm 3 -  75 Nm   WARNING Do not renew bolts yet or tighten to their final torque. This will be done when installing the gearbox.   Note

The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged. –  Disconnect exhaust system at clamps -arrows-.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to rear cross member from below (place a block of wood -arrow- between lifting column and cross member). –  Support rear cross member with engine and gearbox jack -V.A.G 1383 A-. –  First unscrew bolts -1- and -2-, then bolts -3- and -4-.

–  Slowly lower rear cross member with engine and gearbox jack -V.A.G 1383 A-.   Note Do not lower the gearbox too far: the distance between the rear cross member and the body (dimension -x-) must not be more than 60 mm. Otherwise, the propshaft joint and the flexible joint in the front exhaust pipe could be damaged. If necessary, tighten spindle of support bracket -10-222 A- so that dimension -x- is not exceeded.

–  Remove heat shields -arrow- for drive shafts (left and right). –  Unbolt drive shafts from gearbox flanges.   Note Make sure you do not damage surface coating on drive shafts.

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

–  Detach Lambda probe wiring on gearbox at the points marked with -arrows-.   Note In the illustration the engine/gearbox assembly has been removed.

–  Unscrew bolt -arrow- at bracket for front exhaust pipe (left-side).

–  Remove nuts -1 … 3- securing front exhaust pipe to exhaust manifold (left-side).   Note Shown in illustration with engine removed. –  Detach front exhaust pipe from exhaust manifold (left-side). –  Remove front exhaust pipe.

–  Unscrew bolt -arrow- at bracket for front exhaust pipe (right-side).

–  Remove nuts -1 … 3- securing front exhaust pipe to exhaust manifold (right-side).   Note Shown in illustration with engine removed. –  Remove front exhaust pipe.

–  Unbolt heat shield for propshaft -arrows-.

–  Remove bolts -arrows- at gearbox/propshaft flange. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Allow propshaft to rest on rear section of exhaust system.

–  Unscrew two nuts -arrows- and detach tunnel cross member.

–  Unscrew nut -1- and pull gearbox selector lever -2- off gearbox selector shaft.

–  Unplug connector -arrow- for reversing light switch -F4- on right side of gearbox and move electrical wiring clear.

–  Unbolt starter -1--arrows- and pull it away from bell housing. –  Remove remaining engine/gearbox bolts. Leave 2 bolts screwed in hand-tight.

–  Unbolt bracket for front exhaust pipe (left-side) on gearbox -arrows-.

–  Drill a hole of 10.2 mm Ø -arrow- in supporting element of gearbox support -3282-.

–  To remove manual gearbox 0A3, four-wheel drive, set up gearbox support -3282- with adjustment plate -3282/38- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The positions of the support elements -arrows- are shown on the adjustment plate in schematic form (the arrow points in direction of travel). t  The adjustment plate can only be fitted in one position.

–  Align the adjustment plate parallel to the gearbox. –  Secure the supporting elements to the left side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on right side- to 20 Nm.

–  Secure the supporting elements to the right side of the gearbox, as shown in illustration. Tighten bolt M10x20 -arrow on left side- to 20 Nm. –  Remove 2 last engine/gearbox bolts. –  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 line to clutch slave cylinder is not damaged.

–  Remove clutch slave cylinder -arrow- and secure with wire; do not open hydraulic system.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Lower gearbox completely.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  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-.