Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 2.7 ltr. TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Spindle -10 - 222 A /11-

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   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. –  Bring wheels into straight-ahead position. –  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal → Rep. gr.27.

–  Remove engine cover panel -arrows-.

–  Detach noise insulation -1- from wheel housing (both sides).

–  Loosen fasteners -1 … 3- and remove noise insulation panels.   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 bolt -1- for hydraulic fluid pressure 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:

–  Remove front exhaust pipe and particulate filter → Rep. gr.26.

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

–  Remove bolts -2 … 6- securing gearbox to engine (accessible from above).

–  Set up support bracket -10 - 222 A- with rack -10-222 A /1- and spindle -10 - 222 A /11- as shown in illustration.

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.

–  Engage 6th gear by pulling out selector shaft -1- and shifting gear selector lever -2- forwards in direction of -arrow-.

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

–  Remove 6 bolts -arrow- securing clutch module to drive plate (rotate clutch module/drive plate 60° further each time by turning both front wheels).

–  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-.

–  Apply puller -T40160- and pull off gearbox selector lever -1-.

–  Remove bolt -1- for starter from engine side. –  Detach starter from gearbox but do not remove starter. –  Remove remaining engine/gearbox securing bolts -7 … 11-.

–  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.

–  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- = 100 mm (maximum)

–  Partly take up weight of engine with spindle -10 - 222 A /11-.   Note Use stepladder -VAS 5085- for access to spindle -10 - 222 A /11- while vehicle is raised.

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

–  Disconnect electrical connector -1- for gear detector switch -F208- using release tool -T40138- and move wiring clear. –  Remove bolt -2- for push rod.   Note -Item 3- can be disregarded. –  Detach gearbox from engine and lower carefully using engine and gearbox jack -V.A.G 1383 A-. –  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 0B3, front-wheel drive; Rep. gr.30.