Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 8-cyl. petrol engine (RS 5)

Special tools and workshop equipment required

t	Removal lever -80 - 200-

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

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

t	Engine bung set -VAS 6122-

t	Counterhold tool -T10172- with -T10172/5-

t	Gearbox support -T40173-

Preparing gearbox support -T40173-: –  Mounting block attached at -position 1- must be removed. –  Mounting block attached at -position 2- must be rotated so that the longer side faces upwards, as shown in illustration. Removing   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Bring wheels into straight-ahead position.

–  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal →  Electrical system; Rep. gr.27.

Vehicles with hydraulic power-assisted steering: –  Extract power steering hydraulic fluid from reservoir -3- with used oil collection and extraction unit -V.A.G 1782-.   Note -Items 1, 2, and 4- can be disregarded.

Continued for all vehicles: –  Remove engine cover panel -arrows-. –  Remove plenum chamber partition panel → General body repairs, exterior; Rep. gr.50.

–  Use removal lever -80 - 200- to press ball socket -2- on selector lever cable off gearbox selector lever. –  Pull off retaining clip -1- and move selector lever cable clear.   Note Do not bend or kink the selector lever cable.

–  Remove bolts -2 … 5- securing gearbox to engine (accessible from above).   Note Item -A- can be disregarded. –  Move electrical wiring harness clear at top of gearbox.

–  Remove both front wheels. –  Remove cover -1- for drive shaft from wheel housing (both sides).

–  Remove noise insulation panels -1- and -2- → General body repairs, exterior; Rep. gr.66.

–  Remove front silencers (left and right) → Engine, mechanics; Rep. gr.26.   Note

Please refer to the vehicle data sticker or the identification on the rear final drive to find out which type of rear final drive is installed in the vehicle. Then select the appropriate Workshop Manual for the rear final drive. –  Remove propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39.

–  Remove subframe cross brace → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.   Caution Risk of damage to parts of the running gear. Do not let the vehicle down on the wheels if the gearbox mounting, steering box and subframe cross brace are not properly installed.

–  Remove bolts (left and right) -arrows- and detach heat shields -1-.

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).

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

–  Remove nut -2-.   Note -Item 1- can be disregarded.

Vehicles with in-line ATF filter: –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Pull off clip -1- and disconnect ATF line. –  Unscrew bolt -4-, detach ATF line -3- from gearbox and place to one side. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.   Note -Item 2- can be disregarded.

–  Remove bolt -1-.   Note Items marked -2- and -arrow- can be disregarded.

Vehicles with exchangeable ATF filter: –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Pull off clip -1- and disconnect ATF line. –  Unscrew bolt -4-, detach ATF line -3- from gearbox and place to one side. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.   Note -Item 2- can be disregarded.

Continued for all vehicles: –  Unplug electrical connectors and move wiring clear: 1 -  to solenoid valve for power assisted steering -N119- (vehicles with hydraulic power assisted steering) 2 -  at engine speed sender -G28-

Caution The gearbox control unit (mechatronic unit) can be damaged by electrostatic discharge. Do not touch contact pins in gearbox connector with bare hands. –  Touch gearbox housing with your hand (without gloves) to discharge any static electricity. –  Turn fastener anti-clockwise -arrow- and unplug electrical connector on gearbox. –  Move wiring harness clear.

–  Detach intermediate steering shaft from steering box and telescope shaft upwards → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48.

–  Remove bolt -1-. –  Press bracket off gearbox and swivel towards rear -arrow-.

–  Remove bolt -1-.   Note -Item 2- can be disregarded.

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

–  To loosen bolts for flywheel, counterhold crankshaft with counter-hold tool -T10172- and -T10172/7-.   Note When you then turn the crankshaft, only turn crankshaft in direction of engine rotation -arrow-.

–  Remove 6 bolts -arrow- for flywheel (turn crankshaft 60° in direction of engine rotation each time).

Vehicles with hydraulic power-assisted steering: –  Place used oil collection and extraction unit -V.A.G 1782- below connection. –  Remove bolts -arrows-, detach hydraulic line -1- from steering box and place to one side. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

Continued for all vehicles: –  Remove bolt -1- and push heat shield for starter slightly to one side.   Note -Item 2- can be disregarded.

–  Remove bolt -1- for starter. –  Detach starter from gearbox but do not remove starter. –  Remove remaining engine/gearbox securing bolts -6 … 10-.   Note Item -A- can be disregarded.

Caution Risk of leaks on ATF oil pan. Do not apply gearbox support -T40173- at ATF oil pan. –  Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- (already prepared) underneath gearbox. Gearbox support must be positioned as follows at front of gearbox: l  On left side of gearbox, mounting block -2- engages in opening for flywheel on gearbox housing. l  On right side of gearbox, gearbox support is applied to differential housing. Place flat rubber block -1- between the two to protect housing.

–  Use tensioning strap -1- to secure gearbox.

–  Remove bolts -arrows- for tunnel cross member.   Note The illustration does not show engine and gearbox jack -V.A.G 1383 A-. –  Detach gearbox from engine and lower carefully using engine and gearbox jack -V.A.G 1383 A-.