Transmission, Removing, AUDI A4, A5, Q5 With 4-Cylinder TDI Engine (Ea 288 Gen I), Pr-TD1

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

Fig 1: Special Tools And Workshop Equipment Required

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Special tools and workshop equipment required

Hose Clamps - Up To 25mm 309494
Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
Engine and Gearbox Jack VAS6931
Brake Piston Retraction Tool T40142
Puller - Gear Shaft Linkage T40160
Gearbox Support T40173

Special tools and workshop equipment required

Hose Clip Pliers VAG1921

Fig 2: Hose Clamp Pliers VAG 1921
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Removing

Fig 3: Identifying Battery

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-- Position the front wheels so they are straight.

-- Turn off the ignition and remove the key.

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

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Follow the steps when disconnecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Carefully remove the engine cover from the retaining pins one after the other -arrows-. Do not pull sharply on the engine cover or pull it to one side.

Fig 4: Removing Engine Cover

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-- Disconnect the connectors -1 and 2-.

Fig 5: Identifying Connectors -1 And 2-

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CAUTION:

There is a risk of destroying the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505-.

If the pressure is too high the connection from the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505- can break.

-- Remove the bolt -3- and push aside the bracket with the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505-.

-- Remove the noise insulations -1- and -2-. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

Fig 6: Under Body Noise Insulation Panels

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A5 Cabriolet:

Fig 7: Identifying Clamping Sleeve

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-- Remove the left and right crossmember. Refer to OVERVIEW - SUBFRAME .

All vehicles:

Fig 8: Identifying Bolt From Power Steering Line

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

CAUTION:

The suspension components could be damaged.

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

Do not support the vehicle on the subframe or on the subframe crossbrace (for example using a floor jack or something similar).

Fig 9: Pressing CV Joint Off Steering Gear And Slide It Up

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CAUTION:

The airbag spiral spring could be damaged.

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.

-- Remove the bolt -arrow- for the universal joint. Refer to OVERVIEW - STEERING COLUMN and OVERVIEW - STEERING GEAR .

-- Press the universal joint off the steering gear and slide it all the way up.

-- Push retainer -arrow- toward the rear, push the release downward and disconnect the connector -2- from the Power Steering Control Module -J500-.

Fig 10: Identifying Connector

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-- Free up the wiring harness.

NOTE:

Ignore -item 1-.

-- Disconnect the connector -1- for the Exhaust Door Control Unit -J883- -item 2- from the catalytic converter.

Fig 11: Identifying Connector And Exhaust Door Control Unit

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NOTE:

Ignore -arrows-.

Fig 12: Clamping Sleeve Threaded Connections

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CAUTION:

The decoupling elements in the front exhaust pipe could get damaged.

Do not bend decoupling elements in front exhaust pipe more than 10°.

-- Loosen the threaded connections -arrows- and slide the clamping sleeves to the rear.

-- Remove the nut -2- and remove the catalytic converter.

Fig 13: Identifying Bolts -1-

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-- If equipped remove the bolts -1- and tie up the front exhaust pipe to the side on the underbody.

-- Disconnect the threaded connection -1-.

Fig 14: Identifying Catalytic Converter

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-- Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in -direction of arrow- into 6th gear.

Fig 15: Identifying Gearshift Assembly

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

Fig 16: Identifying Transmission Lower Cover

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-- Turn the crankshaft over both front wheels 120° in direction of engine rotation and remove the three drive plate bolts -arrow-.

Fig 17: Identifying Clutch Module First Bolt Installation Location

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-- If equipped, remove the left and right noise insulation -1- in the wheel housing.

Fig 18: Driveshaft Cover -1-

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-- If equipped, remove the subframe shield -1- on the left and right side. Remove the bolts -arrows- and remove the heat shields inward.

Fig 19: Identifying Subframe Shield

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

Fig 20: Drive Axle Heat Shield & Bolts

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-- Remove left and right driveshafts from transmission flange shafts.

Fig 21: Identifying Left And Right Drive Axles

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Vehicles with transmission fluid heater

Fig 22: Identifying Coolant Hoses And Hose Clamps 3094

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WARNING:

Risk of burning due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.

Reduce pressure by cover coolant expansion tank cap with cloths and carefully opening.

-- Remove both of the coolant hoses from the transmission with Hose Clamps - Up To 25mm 309494.

-- Place the drip tray underneath the transmission, open the spring clamps -1- and remove both of the coolant hoses.

All vehicles:

Fig 23: Identifying Driveshaft Heat Shield

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-- Remove the bolts -arrows- and remove the driveshaft heat shield (if equipped) for the driveshaft -A-.

-- Remove the driveshaft. Refer to DRIVESHAFT or 39 FINAL DRIVE, DIFFERENTIAL for Sport Differential.

-- Remove the engine/transmission connecting bolts -1- and -6 to 10-.

Fig 24: Engine To Transmission Bolts And Alignment Sleeves

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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 25: Identifying Transmission Holding Fixture

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NOTE:

Be careful not to get the electrical wires caught on the transmission when attaching the tensioning strap.

-- Tension the tensioning strap.

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

Fig 26: Identifying Tunnel Crossmember And Bolts

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-- Loosen the bolts -1- for the torque support -2-.

Fig 27: Identifying Torque Support And Bolts

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-- Lower the transmission with the Engine and Gearbox Jack VAS6931 only until the torque support is completely at the bottom of its adjustment range -arrow-.

-- Re-tighten the bolts for the torque support -1-.

-- Additionally place the Brake Piston Retraction Tool T40142 as a spacer as shown.

-- Remove the bolts -1- and -3-.

Fig 28: Installing Connector On Transmission Range Gear Recognition Switch

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There are different connectors to the Gear Recognition Sensor -G604-. Disconnect the connectors -2- as follows:

-- Press the lock -1- downward, disconnect the connector -2- and free up the wire.

Fig 29: Identifying Gear Recognition Sensor And Harness Connector (From MY 2013)

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Fig 30: Disconnecting Connector From Gear Recognition Sensor

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-- Pry out lock -1- approximately 3 mm with a screwdriver -direction of arrow A-.

-- Press the lock -1- downward -direction of the arrow B-, disconnect the connector -2- and free up the wire.

-- Remove the bolt -2- and remove the clutch slave cylinder from the transmission while doing so disengage the pipe from the bracket.

Fig 31: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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-- Secure the clutch slave cylinder sideways in the engine compartment.

CAUTION:

The clutch slave cylinder could be damaged.

Do not press the clutch pedal after the clutch slave cylinder has been removed.

-- Remove the nut -1-.

Fig 32: Removing Selector Rod Using Puller T40160

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CAUTION:

Danger of causing damage to the gearshift shaft inside the transmission.

Do not pry off the transmission shift lever -1- using a pry bar or hit it with a hammer.

-- Install the Puller - Gear Shaft Linkage T40160 and remove the transmission shift lever -1-.

-- Remove the engine/transmission connecting bolts -3 to 5-.

Fig 33: Engine To Transmission Bolts And Alignment Sleeves

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-- Remove the starter bolt -2-.

-- Remove the starter from the transmission and leave it in the installation position.

NOTE:

It is not necessary to disconnect the starter cable.

The bolt -2- secures the starter on the transmission. A spacer sleeve is located between the starter and the transmission -arrow-.

Fig 34: Identifying Upper Starter Bolt And Spacer Sleeve

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

Fig 35: Identifying Transmission Holding Fixture

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NOTE:

Pay attention to driveshaft clearance when lowering.

Unclip the wires from the top of the transmission.

If the transmission removed is being replaced, then the following components must be changed:

Fig 36: Attach Exhaust System Retaining Strap Bracket To New Transmission

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Bracket -1- for the exhaust system retaining strap. Refer to EXHAUST PIPES/MUFFLERS for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, EXHAUST PIPES/MUFFLERS for 3.0L, engine codes CCBA, CGXC, CTUB, or EXHAUST PIPES/MUFFLERS for 3.2L, engine code CALA .
Tunnel crossmember with the transmission mount and transmission support. Refer to OVERVIEW - SUBFRAME MOUNT .
If necessary remove the clutch module. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

Fig 37: Removing/Installing Flywheel Components
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