Audi Workshop Service and Repair Manuals

Removing gearbox - vehicles with 3.2 ltr. FSI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

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-

Special tools and workshop equipment required

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

t  Release tool -T40138-

t  Removal lever -80 - 200- t  Engine support bracket, basic set -T40091- t  Engine support bracket, supplementary set -T40093- Removing Proceed as follows:   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. –  Switch off ignition and take out ignition key. –  Disconnect battery → Rep. gr.27.

–  Remove engine cover panel (rear) -arrows-. –  Remove both front wheels.

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

–  Loosen fasteners -1, 2, 3, 4- and remove noise insulation panels. –  Remove front silencer (left and right) → Rep. gr.26. –  Remove plenum chamber partition panel → Rep. gr.50.

–  Remove nuts -arrows- and bolt -1- and press catalytic converter to right side.   Note For illustration purposes, the installation position is shown with the engine removed.

–  Remove bolts -2 … 6- securing gearbox to engine (accessible from above). –  Attach a nut loosely to catalytic converter (right-side) to prevent it from dropping.

–  Set up support bracket -10 - 222 A- with connecting piece -T40091/3- on suspension turrets (left and right), as shown in illustration. –  Hook spindle -10 - 222 A /11- onto engine lifting eye (right-side).

–  Attach remaining parts of support bracket -10 - 222 A- as shown in illustration. Set up support -T40093/3- on metal flange of longitudinal member. –  Hook spindle -10 - 222 A /11- onto engine lifting eye (front left).

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.

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

–  Disconnect electrical connector -2- for engine speed sender -G28- and move wiring clear.   Note -Item 1- can be disregarded.

–  If fitted, remove bolts -arrows- and detach heat shield -A- for propshaft.

–  Hold propshaft with counterhold tool -T10172- and adapters -T10172/5- to prevent it from turning.   Note On vehicles with propshaft with splines on gearbox end, counterhold at rear final drive in the same way.

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

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

–  Remove 6 bolts -arrow- for drive plate (turn both front wheels so that clutch module rotates 60° in direction of engine rotation each time).

Propshaft with bolted connection at gearbox end: –  Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool -T10172- and -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to one side. Propshaft with splined connection at gearbox end: –  Remove propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BD; Rep. gr.39.

Continued for all vehicles –  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).   Note The installation position is shown with the gearbox removed.

–  Remove bolts -arrows- and detach heat shield for drive shaft (left-side).   Note The installation position is shown with the gearbox removed.

–  Unbolt drive shafts (left and right) from flange shafts on gearbox.

–  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-.

Caution Risk of damage to selector shaft in gearbox. t  Do not prise off or knock off the gearbox selector lever -1- with a lever or hammer. t  Always use puller -T40160- when removing the gearbox selector lever. –  Fit puller -T40160- and pull off selector rod -1-.

–  Remove bolt -1-, press retainer off gearbox and swivel back towards rear -arrow-.

–  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 bolt -4- for starter from engine side. –  Detach starter from gearbox but do not remove starter.   Note t  Starter cables -2- and -3- do not need to be disconnected. t  -Item 1- can be disregarded.

–  Remove remaining engine/gearbox securing bolts -7 … 11-.

–  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) –  Pre-tension threaded spindles on support bracket -10 - 222 A- slightly.

–  Disconnect electrical connector -1- for gear detector switch -F208- using release tool -T40138- and move electrical wiring clear. –  Remove bolt -2- for push rod. –  Remove bolt -3- for connecting rod. –  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  Clutch module (if applicable) → Servicing 6-speed manual gearbox 0B2, four-wheel drive; Rep. gr.30. t  Tunnel cross member, gearbox mounting and gearbox support → Chapter.