Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 4.2 ltr. FSI engine

Special tools and workshop equipment required

t	Removal lever -80 - 200-

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

t	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

t	Counter-hold tool -T10172- with -T10172/5- and -T10172/7-

t	Gearbox support -T40173-

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

–  Remove engine cover panel -arrows-. –  Remove plenum chamber partition panel → Rep. Gr.50.

–  Remove bolts -arrows-. –  Unplug electrical connector at coolant shortage indicator switch -F66- and move coolant expansion tank to one side with coolant hoses -1, 2, 3- attached.   Note

Place a cloth below to catch escaping ATF. –  Unscrew bolt -2- and nut -3-.   Note -Items 1 , 4, 5, 6- can be disregarded.

–  Remove bolts -2 … 5- securing gearbox to engine (accessible from above).

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

–  Remove noise insulation panels → General body repairs, exterior; Rep. Gr.66.

–  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.

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 on gearbox.   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 or subframe cross brace are not properly installed.

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 bolt -2- (left and right).   Note -Item 1- can be disregarded.

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

Continued for all vehicles:   Caution Risk of damage to coil connector for airbag. t  Front wheels must be in straight-ahead position when steering column 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). –  Move steering wheel as far as possible downwards and to the rear, making use of the full range of the steering column adjuster. –  Turn steering wheel to centre position (wheels in straight-ahead position) and lock. –  Unscrew bolt -arrow- for steering column → Running gear, front-wheel and four-wheel drive; Rep. Gr.48. –  Press steering column off steering box and push all the way up.

–  Unplug electrical connectors -1- on steering box and -2- for engine speed sender -G28- and move electrical wiring clear.

–  Use removal lever -80 - 200- to pry ball socket -1- on selector lever cable off selector shaft lever. –  Pry off retaining clip -2- and detach selector lever cable from gearbox.   Note Do not bend or kink the selector lever cable.

–  Remove bolt -2-. –  Push retaining bracket in direction of -arrow B- and pivot to the rear -arrow A-.

–  Remove bolts -1- and -2- and detach retaining bracket with spring. –  Unscrew bolts -arrows- and detach bracket.

Caution The flexible joints in the front silencer can be damaged. The flexible joints in the front silencer must not be bent further than 10°. –  Unfasten clamps -1- and -2-, slide towards rear and tie front silencers (left and right) to noise insulation panels (left and right) with cable ties.

–  Remove bolts -arrows- and detach heat shield for propshaft.

–  Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool -T10172- with -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to one side.   Note

Place a cloth below to catch escaping ATF. –  Remove bolts -1, 4, 5, 6-. –  Press ATF pipe to one side. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.   Note -Item 2- and -item 3- can be disregarded.

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

–  To loosen bolts for torque converter, 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 torque converter (turn crankshaft 60° in direction of engine rotation each time).

–  Remove starter → Electrical system; Rep. Gr.27.   Note The starter must be removed so that the end seal -1- can be fitted correctly in the starter aperture when installing the gearbox.

–  Remove remaining engine/gearbox securing bolts -6 … 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.   Note

For illustration purposes, the gearbox support -T40173- is not shown. –  Remove bolts -arrows- for tunnel cross member.

–  Detach gearbox from engine and lower carefully using engine and gearbox jack -V.A.G 1383 A-.