Transmission, Removing, 4.2L FSI Engine

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Pry Lever 80-200
Engine and Gearbox Jack VAS6931
Step Ladder VAS5085
Engine Bung Set VAS6122
Counterhold - Kit - Multiple Use T10172 with Counterhold - Kit - Adapters 5 T10172/5Counterhold - Kit - Adapter 7 T10172/7.
Gearbox Support T40173

Removing

-- Position the front wheels so they are straight.

-- Turn off the ignition and remove the key.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover -arrows-.

Fig 1: Identifying Engine Cover

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-- Remove the plenum chamber bulkhead. Refer to Bulkhead .

-- Remove the bolts -arrows-.

Fig 2: Identifying Coolant Hose And Coolant Reservoir

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-- Disconnect the connector on the Engine Coolant Level Warning Switch -F66- and move the coolant reservoir to the side with the coolant hoses -1, 2 and 3- still connected.

NOTE:

Catch any leaking ATF with a cloth.

Fig 3: Identifying Bolts And Nuts

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-- Remove the bolt -2- and the nut -3-.

NOTE:

Ignore -1, 4, 5 and 6-.

-- Remove the bolts -2 through 5- connecting the engine to the transmission. They are accessible from above.

Fig 4: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Remove the left and right front wheels.

Fig 5: Identifying Right Drive Axle Cover

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-- Remove the left and right drive axle cover -1- inside the wheel housing.

-- Remove the noise insulations. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

Fig 6: Identifying Noise Insulation

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-- Remove the bolts -arrows- and remove the heat shield from the right drive axle.

Fig 7: Drive Axle Heat Shield & Bolts

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-- Remove the bolts -arrows- and the left drive axle heat shield.

Fig 8: Identifying Bolts And Left Drive Axle Heat Shield

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-- Remove left and right drive axles from transmission flange shafts.

Fig 9: Identifying Transmission Connector

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch the transmission housing (without wearing gloves).

-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector from the transmission.

-- Free up the electrical wiring harness on the transmission.

CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

All A4; A5 Coupe

Fig 10: Locating Power Steering Hydraulic Line

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-- Remove the nut -1- from the power steering hydraulic line.

-- Remove the bolts -arrows- and remove the subframe crossbrace.

A5 Cabriolet

Fig 11: Identifying Clamping Sleeve

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-- Remove the left and right bolt -2-.

NOTE:

Ignore item -1-.

-- Remove the bolt -2- for the power steering hydraulic line.

Fig 12: Identifying Bolt For Power Steering Hydraulic Fluid Line Bracket

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-- Remove the bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Fig 13: Locating Universal Joint Bolt

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CAUTION:

The airbag spiral spring could be damaged.

Remove the steering column from the steering gear only when the front wheels are in the straight-ahead position.
Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.

-- Lower the steering wheel as far as possible.

-- Turn the steering wheel into its center position (wheels in the straight-ahead position) and secure it.

-- Remove the bolt -arrow- for the steering column. Refer to OVERVIEW - STEERING COLUMN .

-- Remove the steering column from the steering gear and push it all the way up.

-- Disconnect the connectors -1- to the steering gear and -2- from the Engine Speed Sensor -G28-.

Fig 14: Disconnect Connector From Servotronic Solenoid Valve

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-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 15: Ball Socket And Securing Clips

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-- Press the securing clips -2- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Remove the bolt -2-.

Fig 16: Identifying Bolt -2-, Removal

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-- Press the tab in direction of -arrow B- and move it to the rear -arrow A-.

-- Remove the bolts -1 and 2- and remove the tab with the spring.

Fig 17: Identifying Bolts And Tab With Spring

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-- Remove the bolts -arrows- and the bracket.

Fig 18: Identifying Bolts - Vehicles With Dual Exhaust System

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CAUTION:

The decoupling elements in the front muffler could get damaged.

Do not bend the decoupling elements in the front muffler more than 10°.

-- Loosen the clamping sleeves -1 and 2-, slide them back and tie up the left and right front mufflers to the left and right noise insulation with cable ties.

-- Remove the bolts -arrows- and remove the driveshaft heat shield.

Fig 19: Driveshaft Heat Shield

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-- Counterhold the driveshaft using Counterhold - Kit - Multiple Use T10172 with Counterhold - Kit - Adapters 5 T10172/5 and remove the bolt attaching the driveshaft to the transmission.

Fig 20: Counterholding Driveshaft Using T10172 And T10172/5

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-- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

-- Secure the driveshaft to the side.

NOTE:

Catch any leaking ATF with a cloth.

Fig 21: Identifying Bolts And Nuts

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-- Remove the bolts -1, 4, 5 and 6-.

-- Move the ATF pipe to the side.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

NOTE:

Ignore -2 and 3-.

-- Remove the lower cover -1- from the transmission -arrow-.

Fig 22: Identifying Transmission Lower Cover

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-- Counterhold the crankshaft with the Counterhold - Kit - Multiple Use T10172 with Counterhold - Kit - Adapter 7 T10172/7 to loosen the torque converter bolts.

Fig 23: Counter Hold Crankshaft With T10172 With T10172/7 To Flywheel Bolts

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NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

-- Remove the six torque converter bolts -arrow- while turning the crankshaft 60° further in the direction of engine rotation.

Fig 24: Identifying Clutch Module First Bolt Installation Location

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-- Remove the bolt -1- from the bottom of the starter on the engine side.

Fig 25: Locating Starter Bolt & Locking Piece

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-- Remove the starter -A- from the transmission.

-- Remove the engine/transmission connecting bolt -arrow 2-.

NOTE:

Locking ring -B- can fall out after removing the starter.

-- Remove the remaining bolts -6 through 10- that attach the engine to the transmission.

Fig 26: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Place the Engine and Gearbox Jack VAS6931 with the Gearbox Support T40173 under the transmission and secure with the tensioning strap -1- as shown in the illustration.

Fig 27: Mount Transmission Onto T40173 And Secure It Using Tension Strap

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NOTE:

The Gearbox Support T40173 is not illustrated.

Fig 28: Identifying Tunnel Crossmember

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-- Remove the bolts from the tunnel crossmember -arrows-.

-- Press the transmission off the engine and lower it carefully using the Engine and Gearbox Jack VAS6931.

Fig 29: Mount Transmission Onto T40173 And Secure It Using Tension Strap

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