Transmission, removing (vehicles with 4-cylinder engine)

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools -- Transmission, Removing From Vehicles

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Special tools, testers and auxiliary items required

Support bracket 10 - 222 A
Transmission support 3282
Adjustment plate 3282/43
Torque wrench V.A.G 1331

Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A

Special tools, testers and auxiliary items required

Fig 2: Insert Pad For Front Fender T40045

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Insert pad for front fender T40045
Grease for clutch plate splines G000100
Copper grease Z381351TE

Procedure

NOTE:

All cable ties which are released or cut open during removal must be installed in the same position when installing.
Heat insulation sleeves removed during removal of transmission must be installed in the same position when installing.

CAUTION:

Follow steps required when disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

Fig 3: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect battery Ground ( GND) strap - arrow -.

Vehicles with 1.8 liter. turbo engine:

Fig 4: Removing Engine Cover

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Remove engine cover panel - arrows -.

Fig 5: Removing Engine Cover

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Vehicles with 2.0 liter. turbo engine:

Remove engine cover panel - arrows -.

Fig 6: Upper Engine/Transmission Securing Bolts

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Remove upper engine/transmission securing bolts - arrows 1 - and - arrows 2 -. Please note that retaining brackets for wires/lines and coolant pipe may be secured on bolts - arrows2 - (important for installation).

Fig 7: Placing Insert Pad For Front Fender T40045 On Both Sides Between Fender Attachment Edge And Web Plate Lying Beneath

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Remove rubber seal from edges of fenders mounting flanges.
To avoid damaging edges of the fender panels use support bracket 10-222 A, insert insert pad for front fender T40045 on both sides between the fender mounting flange and the body panel underneath.

Fig 8: Engine Support Bridge 10-222 A Set Up With Adapters 10-222/3 On Fender Mounting Flanges

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Set up support bracket 10-222 A with adapters 10-222/3 on fender mounting flanges.
Engage spindles on engine lifting eyes as illustrated.
Take up weight of engine using spindles.

Fig 9: Fasteners

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On vehicles equipped with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary heater to sound insulation.

Fig 10: Front And Rear Sound Insulation And Fasteners

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Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.

Fig 11: Removing Noise Insulation Bracket

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Detach bracket - arrow - for sound insulation.

Fig 12: Drive Axle Heat Shield

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Remove heat shield - arrows - for drive axle (right-side).
Remove drive axles (left and right) from transmission flange shafts.

Make sure you do not damage surface coating on drive axles.

Fig 13: Locating Clamping Sleeve

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NOTE:

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Separate exhaust system at clamp - arrow - and slide clamp to rear.

Fig 14: Retaining Bracket For Front Exhaust Pipe, Bolt And Nut

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Remove bolt - 1 - and nut - 2 - and detach retaining bracket for front exhaust pipe.

Fig 15: Identifying Driveshaft Shield

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If installed, remove heat shield for drive axle - arrows -.

Fig 16: Locating Bolts At Transmission/Drive Shaft Flange

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Remove bolts - arrows - at transmission/drive shaft flange.
Slide drive shaft together towards rear final drive. The constant velocity joints can be moved axially.
Tie drive shaft to side.

Fig 17: Torque Reaction Support

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Cabriolet:

NOTE:

On Audi Cabriolet vehicles the following additional steps are required in order to remove the three bottom engine/transmission bolts:

Remove torque reaction support - arrows -.

Fig 18: Swivel Stabilizer Bar Nuts, Engine Mountings Nut And End Of Stud

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Unscrew nuts - 1 - on left and right sides, and swivel anti-roll bar - 2 - downwards.
Loosen nut - 3 - on left and right engine mountings until bottom of nut is flush with stud - arrow -.
Use support bracket 10 - 222 A to lift engine just enough for nuts - 3 - to make contact with left and right console.

Fig 19: Three Lower Engine And Transmission Connecting Bolts

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Continued for all vehicles:

Remove three lower engine/transmission securing bolts - arrow -.

Cabriolet:

Lower engine back down.

Fig 20: Locating Starter Bolt

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Continued for all vehicles:

Detach starter from engine/transmission and secure if necessary →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

NOTE:

Starter cables do not have to be disconnected.

Fig 21: Hole In Supporting Elements Of Transmission Support 3282

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Drill a hole of 10.2mmdiameter - arrow - in supporting elements of transmission support 3282.

Fig 22: Support Elements 3282/49 And 3282/52 And Arrow On The Adjustment Plate

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To remove manual transmission 02X, set up transmission support 3282 with adjustment plate 3282/43 and place on engine/transmission jack V.A.G 1383 A.

NOTE:

The support elements 3282/49 - arrows A - and 3282/52 - arrows B - are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points toward the direction of travel.
Adjustment plate can only be installed in one position.

Fig 23: Supporting Elements Secured To Left Side Of Transmission

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Align adjustment plate parallel to transmission.
Secure supporting elements to the left side of the transmission, as shown in illustration. Tighten bolt - arrow on right side - to 20 Nm.

Fig 24: Supporting Elements Secured To Right Side Of Transmission

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Secure supporting elements to the right side of the transmission, as shown in illustration. Tighten bolt - arrow on left side - to 20 Nm.

Fig 25: Tunnel Cross Member Mounting Bolts

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First remove bolts - 1 - and then bolts - 2 -.

Fig 26: Removing Nuts And Rear Crossmember

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Remove nuts - arrows - and detach tunnel cross member.
Lower transmission slightly using engine/transmission jack V.A.G 1383 A.

Fig 27: Back-Up Light Switch F4 Electrical Connector

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Disconnect electrical connector - arrow - for back-up light switch F4 and move electrical wire clear.

Fig 28: Identifying Push Rod And Connecting Rod For Selector Rod

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Remove connecting rod - 2 - for selector rod.
Remove push rod - 1 - by using an 8 mm hex key when unscrewing bolt.

Fig 29: Selector Shaft Lever Nut

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Remove nut - arrow - and detach selector shaft lever from selector shaft.

Fig 30: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed

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Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.
Press transmission off dowel sleeves and lower carefully using engine/transmission jack V.A.G 1383 A just far enough to gain access to slave cylinder.

NOTE:

When lowering transmission, make sure hydraulic line to slave cylinder is not damaged.

Fig 31: Slave Cylinder Bracket And Fastener

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Remove slave cylinder from transmission - arrow - and secure with wire. Do not open line/hose system.

CAUTION: Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

If installed, remove retaining clips/cable ties together with Lambda probe wires from top of transmission.
Lower transmission.

NOTE:

When lowering transmission, make sure there is sufficient clearance to drive shafts.

Before performing assembly work, secure transmission to assembly stand, using holding fixture VW 540 → Transmission, mounting on assembly stand .

Fig 32: Transmission Mounting

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If installing a new transmission instead of the one removed, the transmission mounting has to be transferred to new transmission - arrows -.

Installing transmission → Transmission, installing (vehicles with 4-cylinder or 6-cylinder engine)