Front Final Drive, Removing And Installing: Removing

Fig 1: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

-- Activate the vehicle lift mode if the vehicle has air suspension. Refer to Self-Leveling Suspension .

-- Remove the left and right front wheel housing liners. Refer to Exterior Equipment .

-- Remove the air filter housing. Refer to Multiport Fuel Injection .

-- Remove both front wheel. Refer to WHEELS AND TIRES .

Fig 2: Identifying Front/Rear Noise Insulation

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-- Remove the bolts and the front -1- and rear -2- noise insulation.

-- Remove the noise insulation bracket -arrows-.

Fig 3: Identifying Bracket For Noise Insulation

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-- If equipped, remove the right heat shield from the front final drive -arrows-.

Fig 4: Identifying Heat Shield Bolts -Arrows- And Shield

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-- Remove the front Drive Axle. Refer to FRONT DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove each Drive Axle from the front final drive. Refer to Front Suspension .

-- Disconnect the connector -arrow- from the steering gear.

Fig 5: Identifying Electrical Connector -Arrow- On Steering Gear

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-- Remove heat shield -A- from the steering gear.

Fig 6: Identifying Steering Gear Heat Shield -A-

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CAUTION:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change steering wheel position and steering gear position any more.

-- Remove the bolt -B- from the universal joint. Refer to Steering .

-- Remove the universal joint from the steering gear.

-- Free up the coolant hoses -arrow-.

Fig 7: Identifying Coolant Hoses -Arrow-

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-- Mount the Engine Support Bridge10-222A with the Engine Support Bridge - Sub-frame Adapter10-222A/22 and connections T40091/3 on the fender bolting edge.

Fig 8: Identifying 10 - 222 A With 10 - 222 A /22 And T40091/3

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-- Install the additional Engine Support Bridge10-222A parts as illustrated. Mount the Engine Support Bridge - Engine Support 1910-222A/19 on the notches in the longitudinal members.

Fig 9: Engaging 10 - 222 A /10 In Rear Engine Lifting Eyes

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-- Attach the Engine Support - Bracket w/Spindle and Hook10-222A/10 to both rear engine lifting eyes.

-- Slide the support T40091/2 with both sliders T40093/5 into both mounts T40093/4.

Fig 10: Sliding T40091/2 With Both Slides T40093/5 Into Both T40093/4

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-- Attach the spindles 10-222A/11 to both front engine lifting eyes as illustrated.

WARNING:

Secure the T40091/2 with the bolts and the splints from the T40093/4.

-- Raise engine slightly by tensioning all spindles evenly in order to achieve even weight distribution.

-- Clamp off the return line -1- and intake hose -2- on the reservoir Hose Clamps - Up To 25mm3094.

Fig 11: Clamping Off Return Line -1- And Suction Line -2- At Hydraulic Fluid Reservoir Using 3094

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NOTE:

To collect escaping hydraulic oil, lay a clean cloth under the separating point.

Fig 12: Identifying Power Steering Fluid Hose Clamp -2- And Banjo Bolt -1-

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-- Remove the banjo bolt -1-.

NOTE:

Ignore -2-.

-- Position the Engine/Gearbox JackVAG 1383A under the subframe.

Fig 13: Identifying Engine-/Gearbox Jack V.A.G 1383 A

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Fig 14: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

CAUTION:

To avoid axle alignment later, subframe must be secured with Assembly Carrier Locating PinsT10300.

-- Secure the subframe with the Assembly Carrier Locating PinsT10300. Refer to Front Suspension .

-- Support the subframe and remove the bolts -2- and -4- diagonally and in steps.

-- Lower to subframe with the front final drive to dimension -a- using the Engine/Gearbox JackVAG 1383A.

Fig 15: Lifting Engine/Transmission Subassembly Using Scissor Lift Platform VAS 6131 Until Dimension Is Reached

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-a- = 200 mm

NOTE:

If necessary, pull subframe down slightly.

-- Remove the threaded connectors -1, 2 and 3- from the front final drive -A- /subframe -B-.

Fig 16: Identifying Bolts With Nuts For Front Final Drive On Subframe, Removal/Installation

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NOTE:

To remove the front final drive, use and additional technician.

Fig 17: Identifying Front Final Drive Rearward Between Subframe And Engine/Transmission, Removal

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Remove the front final drive -1- toward the rear between the subframe and the engine/transmission subassembly:

-- Tie up the left Drive Axle.

-- With a 2nd technician, remove the front final drive from the mounts in subframe while guiding the right Drive Axle out of the flange shaft.

-- Lift the front final drive over the steering gear and guide it out toward the rear.

Fig 1: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

-- Activate the vehicle lift mode if the vehicle has air suspension. Refer to Self-Leveling Suspension .

-- Remove both front wheel. Refer to WHEELS AND TIRES .

-- Remove the left and right engine hood seal -1- -arrow-.

Fig 2: Left And Right Hood Seal -1- -Arrow- Removal

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Vehicles with a 3.0L TDI engine:

Fig 3: Identifying 10 - 222 A Mounted On Fender Bolting Edge

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-- Mount the Engine Support Bridge10-222A on the fender bolting edge as illustrated.

The Lifting Tackle3033 spindles are in the back.

-- Engage the spindle carabiner hook into the rear engine lifting eyes.

-- Preload the engine slightly by tensioning all spindles evenly in order to achieve an even weight distribution.

Vehicles with a 4.2L TDI Engine:

Fig 4: Removing Engine Hood Seal

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-- Loosen the bolt -1-. Remove the bolt -2- and nut.

-- Free up the right rear coolant pipe on the rear right engine lifting eye.

NOTE:

Ignore -arrows-.

-- Mount the Engine Support Bridge10-222A on the fender bolting edges with 2 threaded spindles -1- from the Lifting Tackle3033 as illustrated.

Fig 5: Disconnecting Return Line And Intake Hose

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-- Engage the spindle carabiner hook into the rear engine lifting eyes.

-- Preload the engine slightly by tensioning all spindles evenly in order to achieve an even weight distribution.

-- Disconnect the return line -1- and intake hose -2- from the reservoir hose using Hose Clamps - Up To 25mm3094.

Fig 6: Clamping Off Return Line -1- And Suction Line -2- At Hydraulic Fluid Reservoir Using 3094

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Vehicles with a 3.0L TDI Engine:

Fig 7: Identifying Power Steering Pump Hydraulic Hose -1- And Bolts -2-

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NOTE:

To collect escaping hydraulic oil, lay a clean cloth under the separating point.

-- Disconnect the power steering pump hydraulic hose -1- using Hose Clamps - Up To 25mm3094.

-- Remove bolts -2- and then remove hydraulic lines from the power steering pump.

-- Seal any open lines and connections with a clean plug from the Engine Bung SetVAS 6122.

Continuation for All:

Fig 8: Identifying Front/Rear Noise Insulation

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-- Remove the bolts and the front -1- and rear -2- noise insulation.

-- Remove the noise insulation bracket -arrows-.

Fig 9: Identifying Bracket For Noise Insulation

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-- If equipped, remove the right heat shield from the front final drive -arrows-.

Fig 10: Identifying Heat Shield Bolts -Arrows- And Shield

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-- Remove the front Drive Axle. Refer to FRONT DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove each Drive Axle from the front final drive. Refer to Front Suspension .

-- Disconnect the connector -arrow- from the steering gear.

Fig 11: Identifying Electrical Connector -Arrow- On Steering Gear

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-- Remove heat shield -A- from the steering gear.

Fig 12: Identifying Steering Gear Heat Shield -A-

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CAUTION:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change steering wheel position and steering gear position any more.

-- Remove the bolt -B- from the universal joint. Refer to Steering .

-- Remove the universal joint from the steering gear.

Version 1:

Fig 13: Coolant Hose Location

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-- Free up coolant hoses -arrow-.

Version 2:

Fig 14: Coolant Hose Location

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-- Free up coolant hoses -arrow-.

Vehicles with a 4.2L TDI Engine:

Fig 15: Removing Hydraulic Line Bolts

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NOTE:

To collect escaping hydraulic oil, lay a clean cloth under the separating point.

-- Remove bolt -2- and banjo bolt for hydraulic line -1- and lay the hydraulic line to the rear.

-- Seal any open lines and connections with a clean plug from the Engine Bung SetVAS 6122.

All vehicles:

Fig 16: Identifying Engine-/Gearbox Jack V.A.G 1383 A

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-- Position the Engine/Gearbox JackVAG 1383A under the subframe.

Fig 17: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

CAUTION:

To avoid axle alignment later, subframe must be secured with Assembly Carrier Locating PinsT10300.

-- Secure the subframe with the Assembly Carrier Locating PinsT10300. Refer to Front Suspension .

-- Support the subframe and remove the bolts -4-.

-- Lower to subframe with the front final drive to dimension -a- using the Engine/Gearbox JackVAG 1383A.

Fig 18: Lifting Engine/Transmission Subassembly Using Scissor Lift Platform VAS 6131 Until Dimension Is Reached

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-a- = 180 mm

NOTE:

If necessary, pull subframe down slightly.

-- Remove the threaded connectors -1, 2 and 3- from the front final drive -A- /subframe -B-.

Fig 19: Identifying Bolts With Nuts For Front Final Drive On Subframe, Removal/Installation

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NOTE:

To remove the front final drive, use and additional technician.

Fig 20: Removing Front Final Drive

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Remove the front final drive -1- below as follows:

-- With a 2nd technician, remove the front final drive from the mounts in subframe while guiding the right Drive Axle out of the flange shaft.

-- Push the front final drive to the right and remove downward -arrow-.

Fig 1: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

-- Activate the vehicle lift mode if the vehicle has air suspension. Refer to VEHICLE LIFT MODE .

-- Remove the left and right air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Release the retainers -arrows B- and remove the air guide -1- -arrow A-.

Fig 2: Removing Refrigerant Line Clamps Nuts And Bolts

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-- Remove nuts and bolts -arrows- for refrigerant line clamps.

Fig 3: Identifying Coolant Line Retaining Clamp Nuts And Bolts -Arrows-

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NOTE:

To position the T40093/3 on the longitudinal members, lay the refrigerant lines to the side with loosened bolted connections.

-- Disconnect the return line -1- and intake hose -2- from the reservoir hose using Hose Clamps - Up To 25mm3094.

Fig 4: Clamping Off Return Line -1- And Suction Line -2- At Hydraulic Fluid Reservoir Using 3094

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-- Remove the left and right engine hood seal -1- -arrow-.

Fig 5: Left And Right Hood Seal -1- -Arrow- Removal

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-- Tighten the front left retaining strap T40244 to the cylinder head.

Fig 6: Mounting Engine Support Bridge 10-222A To Fender Bolting Edge

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-- Mount the Engine Support Bridge10-222A with the Engine Support Bridge - Sub-frame Adapter10-222A/22 and connectors T40093/4 on the fender bolting edge.

Fig 7: T40091

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-- Assemble the parts from the Engine Support - Basic SetT40091 and Engine Support - Supplement KitT40093A as illustrated.

Fig 8: T40093/3

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NOTE:

Mount the T40093/3 on the notches in the longitudinal members.

-- Slide the support T40091/2 with both sliders T40093/5 into both connectors T40093/4.

Fig 9: Removing Noise Insulation Bolts

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-- Engage the threaded spindle from the Lifting Tackle3033 on the right rear engine lifting eye as illustrated.

WARNING:

Risk of an accident due to loose support bridge parts.

Secure the support T40091/2 with the connector T40093/4 bolt -1- and cotter pin -arrow-.

-- Engage the Engine Support - Bracket w/Spindle and hook10-222A/10 on the left front engine lifting eye and preload it.

-- Lift the engine slightly by tensioning both spindles evenly in order to achieve an even weight distribution.

-- Remove the bolts and the front -1- and rear -2- noise insulation.

Fig 10: Identifying Front/Rear Noise Insulation

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-- Remove the noise insulation bracket -arrows-.

Fig 11: Identifying Bracket For Noise Insulation

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-- Remove the right heat shield from front final drive -arrows-.

Fig 12: Identifying Heat Shield Bolts -Arrows- And Shield

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-- Remove the front Drive Axle. Refer to FRONT DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove each Drive Axle from the front final drive. Refer to [For engine(s) BAR, CTWB, BHK, CATA, CNRB, CTWA, CJWE, CJWC, CJWB] Front Suspension .

-- Disconnect the connector -arrow- from the steering gear.

Fig 13: Identifying Electrical Connector -Arrow- On Steering Gear

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-- Remove heat shield -A- from the steering gear.

Fig 14: Identifying Steering Gear Heat Shield -A-

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CAUTION:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change steering wheel position and steering gear position any more.

-- Remove the bolt -B- from the universal joint. Refer to [For engine(s) BAR, CTWB, BHK, CATA, CNRB, CTWA, CJWE, CJWC, CJWB] Steering .

-- Remove the universal joint from the steering gear.

-- Free up coolant hoses -arrow-.

Fig 15: Identifying Coolant Hoses -Arrow-

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-- Disengage the power steering hydraulic line from the left brackets on the subframe.

-- Remove the nuts -arrows- and free up the power steering hydraulic line -1-.

Fig 16: Removing Ventilation Hose From Differential

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-- Remove the ventilation hose -1- from the differential -arrow-.

Fig 17: VAG 1383A

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-- Position the Engine/Gearbox JackVAG 1383A under the subframe.

Fig 18: Identifying Engine-/Gearbox Jack V.A.G 1383 A

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Fig 19: Identifying Bolts -4- And Engine Carrier Bolts -3-

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WARNING:

Do not remove the Engine/Gearbox Jack - Gearbox Support bolts -1- and the subframe bolts -3- for the following work.

CAUTION:

To avoid axle alignment later, subframe must be secured with Assembly Carrier Locating PinsT10300.

-- Secure the subframe with the Assembly Carrier Locating PinsT10300. Refer to [For engine(s) BAR, CTWB, BHK, CATA, CNRB, CTWA, CJWE, CJWC, CJWB] Front Suspension .

-- Support the subframe and remove the bolts -4-.

-- Lower to subframe with the front final drive to dimension -a- using the Engine/Gearbox JackVAG 1383A.

Fig 20: Lifting Engine/Transmission Subassembly Using Scissor Lift Platform VAS 6131 Until Dimension Is Reached

Courtesy of AUDI OF AMERICA, LLC

-a- = 180 mm

NOTE:

If necessary, pull subframe down slightly.

NOTE:

To collect escaping hydraulic oil, lay a clean cloth under the separating point.

Fig 21: Removing Front Final Drive Threaded Connectors

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-- Counterhold the hex fitting -1- to remove the union nut -2-.

-- Lay the power steering hydraulic line -3- toward the rear.

-- Remove the threaded connectors -1, 2 and 3- from the front final drive -A- /subframe -B-.

Fig 22: Identifying Bolts With Nuts For Front Final Drive On Subframe, Removal/Installation

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NOTE:

To remove the front final drive, use and additional technician.

Fig 23: Removing Front Final Drive

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Remove the front final drive -1- below as follows:

-- With a 2nd technician, remove the front final drive from the mounts in subframe while guiding the right Drive Axle out of the flange shaft.

-- Push the front final drive to the right and remove downward -arrow-.