Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

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	Counterhold tool -T10355-

t  Gearbox support -T40173- Procedure –  Bring wheels into straight-ahead position.

Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27.

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

–  Set up support bracket -10 - 222 A- with adapter -10 - 222 A /3- on suspension turrets (left and right), as shown in illustration. –  Hook spindle -10 - 222 A /11- onto engine lifting eyes.

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

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

–  Remove bolts and detach heat shield -1- for drive shaft (right-side). –  Unbolt drive shafts (left and right) from flange shafts on gearbox.

–  Detach intermediate steering shaft from steering box and telescope shaft upwards → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48.   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, A5 Sportback: –  Remove subframe cross brace → Rep. gr.40.

A5 Cabriolet: –  Remove bolts -1- and -2- (left and right) and detach diagonal strut.

–  Remove subframe cross brace → Rep. gr.40.

Continued for all vehicles: –  Pull cover -1- off bottom of gearbox -arrow-.

–  To slacken bolts for drive plate, counterhold crankshaft with counterhold tool -T10355- at vibration damper.   Note -Arrow- can be disregarded.

–  Remove 3 bolts -arrow- for drive plate (turn crankshaft 120° in direction of engine rotation each time).   Note

Place a cloth below the connection to catch escaping ATF. –  Unscrew bolts -arrows- and detach ATF lines from gearbox. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove engine/gearbox securing bolts -8 … 11-.

–  Use removal lever -80 - 200- to press ball socket -1- on selector lever cable off gearbox selector lever. –  Remove bolts -2- for cable support bracket. –  Move selector lever cable clear.   Note Do not bend or kink the selector lever cable.   Caution The gearbox control unit (mechatronic unit) can be damaged by electrostatic discharge. t  Before handling the electrical connector, the mechanic must discharge static by briefly touching an earthed metal object, such as vehicle earth, lifting platform or heater radiator, etc. t  Do not touch contact pins in gearbox connector with bare hands. –  Turn fastener anti-clockwise -arrow- and unplug electrical connector on gearbox.

–  Remove bolt -2-. –  Push retainer -1- in direction of -arrow B- and pivot to the rear -arrow A-.

–  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.

–  Lower gearbox initially by dimension -a- using engine and gearbox jack -V.A.G 1383 A-. l  Dimension -a- = 60 mm

–  Apply light tension to both spindles -10 - 222 A /11-.

–  Remove remaining engine/gearbox securing bolts -1 … 7-.   Note

t  Bolt -2- also secures the starter to the gearbox and has an additional spacer sleeve -arrow-. t  The spacer sleeve must be fitted between the starter and the gearbox. –  Detach starter from gearbox but do not remove starter.

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