Audi Workshop Service and Repair Manuals

Removing gearbox – vehicles with 4-cylinder diesel engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Ring spanner insert, 16 mm -V.A.G 1332/14-

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

t	Stepladder -VAS 5085-

t	Puller -T40160-

t	Gearbox support -T40173-

t  Release tool -T40138-

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

–  Carefully detach engine cover panel from retaining studs in direction of -arrow-. Pull out engine cover panel evenly, without jerking.

–  Remove noise insulation panels -1- and -2- → Rep. gr.66.

–  Remove noise insulation -1- from wheel housing (right-side).

–  Remove nuts for front exhaust pipe -arrows-.

Caution The flexible joints in the front exhaust pipe can be damaged. The flexible joints in the front exhaust pipe must not be bent further than 10 °. –  Disconnect exhaust system at clamp -arrows- and detach front exhaust pipe.

–  Remove bolts -1- and -2- and detach mounting.

WARNING Risk of scalding from hot steam and hot coolant. t  The cooling system is under pressure when the engine is hot. t  Cover filler cap on expansion tank with a cloth and open carefully to release pressure. –  Drain coolant → Rep. gr.19.

–  Detach seal -arrow-. –  Remove individual components -1, 2, 3- or complete plenum chamber cover (depending on version) → Rep. gr.50.

–  Remove bolt -1- and guide junction box off body brace in direction of -arrow-. –  Unclip electrical connector -2- from body brace.

–  If fitted, unscrew bolts -1- and nuts -2- and remove body brace -3-.

–  Mark coolant hoses -1- and -2- for re-installation and disconnect hoses from connection leading to heat exchanger. –  Unclip coolant hoses together with hose protector grommet from plenum chamber partition panel and push through into engine compartment.   Note Alternatively you can also disconnect the coolant hoses from the coolant pipes on the engine, in which case the coolant hoses can remain in their original position on the plenum chamber partition panel. –  Detach vacuum line connection leading to brake servo at plenum chamber partition panel and remove plenum chamber partition panel → Rep. gr.50.

–  Working from plenum chamber cover, remove bolt -3- for connecting rod.   Note -Items 1 and 2- can be disregarded.

–  Remove air cleaner housing → Rep. gr.23. –  Unscrew nuts -1, 2 and 3- on turbocharger and tie up particulate filter.

–  Remove bolts -3 … 6- securing gearbox to engine (accessible from above).   Note Bolts -3- and -5- also secure brackets for pipes and/or wiring. Tie these brackets onto the engine.

–  Remove top starter bolt -1-. –  Detach spacer sleeve -2- between starter and gearbox.

–  If there are hoses and wire connections in area of engine lifting eyes for support bracket -10 - 222 A-, remove these now. –  Set up support bracket -10 - 222 A- with -10 - 222 A /3- on suspension turrets (left and right), as shown in illustration. –  Hook spindles -10 - 222 A /11- onto engine lifting eyes (rear right and front left).

Caution Risk of damage to coil connector for airbag. t  Front wheels must be in straight-ahead position when universal joint is detached from steering box. t  Do not change position of steering wheel or steering box after this step (if necessary, fix steering wheel in position with adhesive tape). –  Remove bolt -arrow- for universal joint → Rep. gr.48. –  Press universal joint off steering box and push all the way up.

Caution Risk of damage to parts of the running gear. Do NOT let the vehicle down on the wheels if the subframe, steering box or subframe cross brace are not properly installed. Do NOT support the vehicle at the subframe or the subframe cross brace (e.g. with a trolley jack). A4 (all models), A5 Coupé: –  Remove nut -1- for hydraulic line for power steering. –  Remove bolts -arrows- and detach subframe cross brace.

A5 Cabriolet: –  Remove bolts -1- and -2- on left and right and detach brace.

–  Remove bolt -2- for hydraulic fluid line for power steering. –  Remove bolts -1- and -arrows- and detach subframe cross brace.

Continued for all vehicles: –  Engage 6th gear by pulling out selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.

–  Pull cover -1- off bottom of gearbox -arrow-.

–  Remove 3 bolts -arrow- for drive plate (turn both front wheels so that crankshaft rotates 120° in direction of engine rotation each time).

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).   Note The installation position is shown with the gearbox removed.

–  Unbolt drive shafts (left and right) from flange shafts on gearbox.

Vehicles with start/stop system: –  Unplug electrical connector from gearbox neutral position sender -G701--1- and move wiring clear.

Continued for all vehicles: –  Remove bolt -2- and tie up clutch slave cylinder to side in engine compartment.   Caution Risk of damage to clutch slave cylinder. Do not depress clutch pedal after removing slave cylinder. –  Remove nut -1-.

Caution Risk of damage to selector shaft in gearbox. t  Do not prise off or knock off the gearbox selector lever -1- with a lever or hammer. t  Always use puller -T40160- when removing the gearbox selector lever. –  Apply puller -T40160- and pull off gearbox selector lever.

–  Remove bolts -1- and detach torque reaction support from engine.   Note Items marked -2- and -3- can be disregarded.

–  Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- underneath gearbox and secure with tensioning strap -1- as shown in illustration.   Note Make sure no electrical wiring is trapped when attaching tensioning strap.

–  Remove bolts -arrows- for tunnel cross member.

–  Lower gearbox initially only by dimension -a- using engine and gearbox jack -V.A.G 1383 A-. l  Dimension -a- = 80 mm (maximum) –  Pre-tension threaded spindles on support bracket -10 - 222 A- slightly.   Note Use stepladder -VAS 5085- for access to threaded spindles while vehicle is raised.

–  Unclip electrical wire -A- from gearbox -arrows-. –  Unclip bracket -B- with electrical connector -C- for exhaust gas temperature sender 4 -G648- from gearbox and tie clear.

–  Disconnect electrical connector -1- for gear detector switch -F208- using release tool -T40138- and move electrical wiring clear. –  Remove bolt -2- for push rod.   Note Bolt -3- was removed at an earlier stage.

–  Remove bolt -3- for starter from engine side. –  Detach starter from gearbox but do not remove starter.   Note Starter cables do not have to be disconnected.

–  Remove remaining engine/gearbox securing bolts -7 … 10-. –  Press gearbox off engine (approx. 20 mm).

–  Using left-hand spindle of gearbox support -T40173-, tilt gearbox downwards towards the right and guide past diesel particulate filter -arrow A-. At the same time push gearbox slightly to the left. –  Then lower gearbox carefully, guiding gearbox housing past steering pinion/steering box and cover for final drive past subframe -arrow B-.   Note t  When lowering gearbox, make sure that all wires are disconnected on the top of the gearbox. t  When lowering gearbox, make sure there is sufficient clearance from drive shafts.

–  If the removed gearbox is being replaced, the following components must be transferred to the replacement gearbox: t  Bracket -1- for exhaust system mounting → Rep. gr.26. t  Tunnel cross member, gearbox mounting and gearbox support → Chapter.

t  Remove clutch module if necessary → Servicing 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.30.