Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 2.0 ltr. TDI engine

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	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

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.   Caution Risk of damage to the engine cover panel. Pull out engine cover panel evenly, without jerking.

–  Generation I engine: Carefully detach engine cover panel from retaining studs one by one in direction of -arrows-.

–  Generation II engine: Carefully detach engine cover panel from retaining studs one by one in direction of -arrows-.

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

–  Remove bolt -arrow-.   Note -Items 1 and 2- can be disregarded. –  Remove plenum chamber partition panel → General body repairs, exterior; Rep. gr.50.

–  Remove electrical connector -1- from bracket and move clear wiring harness -2- using removal lever -80 - 200-.   Note

Place a cloth below the connection to catch escaping ATF. –  Remove bolts -1- and -2-, detach ATF lines from gearbox and tie up. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolts -2 … 5- securing gearbox to engine (accessible from above).   Note t  Bolts -3- and -5- also secure bracket for pipes and/or wiring. Tie bracket to engine.

t  Bolt -2- also secures the starter to the gearbox and has an additional spacer sleeve -arrow-.

–  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-.

–  Remove trim cap from vibration damper. –  To slacken bolts for drive plate, counterhold crankshaft with angled ring spanner -1- at vibration damper.   Note When you then turn the crankshaft, turn only in direction of engine rotation -arrow-.

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

–  Remove bolt -2- for retainer. –  Push retainer -1- in direction of -arrow B- and pivot to the rear -arrow A-.   Note The particulate filter remains installed.

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

–  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.

–  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.

Caution The flexible joints in the exhaust system can be damaged. The flexible joints at the catalytic converter must not be bent further than 10°. –  Disconnect exhaust system at clamp -arrow-. –  Tie up front exhaust pipe to heat shield below selector mechanism with wire.

–  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-.

–  Remove bolt -1- for starter. –  Detach starter from gearbox but do not remove starter. –  Remove remaining engine/gearbox securing bolts -6 … 10-.

–  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-.