Transmission, removing (vehicles with 6-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

Fig 3: Engine Sling 2024 A

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Lifting aid 2024 A
Grease for clutch plate splines G000100
Copper grease Z381351TE

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 →

Fig 4: Disconnecting Battery Ground (GND) Strap

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

Fig 5: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 6: Removing Front Engine Cover

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Remove front engine cover - arrows -.

Fig 7: Removing Cover In Engine Compartment (Left Side)

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Remove cover - 1 - on left side of engine compartment.

Fig 8: Removing Coolant Hoses

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Unfasten coolant expansion tank - arrow -.
Disconnect electrical wiring for Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
Tie coolant expansion tank to one side, leaving coolant hoses - 1 - , - 2 - and - 3 - connected.

Fig 9: Removing Cover In Engine Compartment (Right Side)

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Remove cover - 1 - on right side of engine compartment.

Fig 10: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct

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Remove bolts - arrows - from solenoid valve mounting plate - 3 -.
Disconnect air intake hose - 1 - from mass air flow sensor.
Pull hose - 4 - for crankcase breather system off air duct - 2 -.

Fig 11: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module

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Remove bolt - arrow - and disconnect air duct - 2 - from throttle valve control module.
If installed, disconnect hose - 1 - from air duct.

NOTE:

In the illustration, the air duct is shown from the rear and with the engine removed.

Remove engine/transmission securing bolts which are accessible from above.

Fig 12: Removing Harness Connectors From Bracket At Left Of Bulkhead

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Disconnect connectors - 1 to 4 - from retainer at left of bulkhead.
Disconnect electrical connectors - 1 - and - 4 -.
Move Lambda probe wires clear.
Remove retainer for connectors.

Fig 13: Left Front Exhaust Pipe To Exhaust Manifold Nuts

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Remove nut - 1 - (access from above), connecting left front exhaust pipe with exhaust manifold.

NOTE:

In the illustration the engine has been removed.

Fig 14: 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 fender mounting flanges.
To avoid damaging edges of fender panels with support bracket 10-222 A, insert insert pad for front fender T40045 on both sides between fender mounting flange and body panel underneath.

Fig 15: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders

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Set up support bracket 10 - 222 A on fender mounting flanges.

Fig 16: Removing Eyelet For 2024A Engine Sling

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Remove eye of lifting tackle 2024A.
Re-insert pin - 1 - in middle hole on lifting tackle and secure it with split pin.
Hook pin on lifting tackle 2024A onto spindle on support bracket 10 - 222 A.
Hook lifting tackle 2024A into lifting eyes at front and rear of engine.

CAUTION: Support hooks and locking pins on lifting tackle must be secured with retainers - arrows - in illustration.

Slightly pretension engine with spindle of support bracket.

Fig 17: Fasteners

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

Fig 18: 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 19: Removing Bracket For Noise Insulation

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Remove bracket for sound insulation - arrows -.

Fig 20: Drive Axle Heat Shield

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Remove heat shield - arrow - for drive axles (left and right).
Remove drive axles from flange shafts, lift clear and secure.

NOTE:

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

Fig 21: Removing Bolts For Front Vehicle Floor Crossmember

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If installed, remove front cross member - 1 to 4 -.

Fig 22: Exhaust System And Clamps

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Disconnect exhaust system at clamps - arrows -.
Remove front exhaust pipe with catalytic converter (left-side) → 26 - EXHAUST SYSTEM, EMISSION CONTROLS for relevant engine code.
Remove bracket for exhaust pipe (right front) from transmission.

Fig 23: Identifying Driveshaft Shield

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

Fig 24: Locating Bolts At Transmission/Drive Shaft Flange

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

Fig 25: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

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Remove nuts - 1 - at bottom of engine mountings (left and right).

Fig 26: Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link

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If installed, unclip operating rod for left front level control system sensor G78 from lower transverse link - arrow -.

Fig 27: Checking Holes Align Using Testing Mandrel 3393

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Before loosening subframe, use testing mandrel 3393 to check whether holes - 1 - and - 2 - are aligned.

If holes are not aligned, a wheel alignment has to be performed after installing the subframe.

Fig 28: Removing Front Bolts From Left And Right Subframe

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Remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
Lower subframe at front.

Fig 29: Three Lower Engine And Transmission Connecting Bolts

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Remove lower engine/transmission securing bolts - arrows -.

Fig 30: Removing Front Bolts From Left And Right Subframe

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Temporarily secure subframe again.

Temporary tightening torque:

1 - approx. 100 Nm

2 - approx. 70 Nm

3 - approx. 70 Nm

CAUTION: Do not replace bolts yet or tighten to their final torque. This will be done when installing the transmission.

Fig 31: Identifying Push Rod And Connecting Rod For Selector Rod

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Remove connecting rod - 2 - for selector rod.
Disconnect push rod - 1 - by removing hex socket head bolt.

Fig 32: 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 33: Selector Shaft Lever Nut

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

Fig 34: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing

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If installed, remove Engine Speed (RPM) sensor G28 from left side of transmission - arrow - and lay aside.

Fig 35: Locating Starter Bolt

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Remove 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 36: Hole In Supporting Elements Of Transmission Support 3282

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

Fig 37: Support Elements 3282/49 And 3282/52 And Arrow On The Adjustment Plate

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To remove transmission 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 correct position.

Fig 38: Supporting Elements Secured To Left Side Of Transmission

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Align adjustment plate parallel to transmission.
Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt M10x20 - arrow on right side - to 20 Nm.

Fig 39: Supporting Elements Secured To Right Side Of Transmission

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Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt M10x20 - arrow on left side - to 20 Nm.

Fig 40: Tunnel Cross Member Mounting Bolts

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Remove bolts - 1 - and then bolts - 2 - at cross member.

Fig 41: Removing Nuts And Rear Crossmember

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Remove nuts - arrows - and detach cross member.

Fig 42: 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 the slave cylinder.

NOTE:

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

Fig 43: 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.

Fig 44: Locating Cable Ties And Oxygen Sensor Wiring At Side

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If installed, open cable ties - arrows A and B - , unclip Lambda probe cables at the side - arrows C - and move cables clear.
Lower transmission.

NOTE:

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

Before carrying out assembly work, secure transmission to assembly stand, using engine and transmission support VW 540 → Transmission, mounting on assembly stand .

Fig 45: Transmission Mounting

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

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