Transmission, Removing, 3.0L TDI Engine

WARNING: This page is about a different car, the 2013 Audi S4, 2012 Audi S4, 2011 Audi S4, and 2010 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine Support Bridge 10-222A
Engine Support Bridge - Engine Bracket 10-222A/1
Engine Support Bridge - Spindle 10-222A/11
Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
Engine and Gearbox Jack VAS6931
Step Ladder VAS5085
Puller - Gear Shaft Linkage T40160
Gearbox Support T40173
Counterhold - Multiple Use T10172A with Counterhold - Kit - Adapters 5-9 T10172/5
Crankshaft Socket T40058
Reversing Light Switch Connector Release Tool T40138
Puller - Clutch Module T40176

Removing

Fig 1: Identifying Battery

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CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Position the front wheels so they are straight.

-- Turn off the ignition and remove the key.

-- Disconnect the battery ground cable -2-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover in direction of -arrows-.

Fig 2: Identifying Engine Covers, Removal

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-- Remove the left and right front wheels.

-- Remove the left and right noise insulation -1- inside the wheel housing.

Fig 3: Driveshaft Cover -1-

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-- Remove the noise insulation by loosening the fasteners -1 through 3-.

Fig 4: Identifying Noise Insulation Components

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-- Remove the front exhaust pipe and the particulate filter .

Fig 5: Identifying Nut

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NOTE:

Ignore item -1-.

-- Remove the connecting rod bolt -2- from the top.

Fig 6: Removing/Installing Connecting Rod Bolt -2-

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-- Remove the bolts -2 through 6- connecting the engine to transmission. They are accessible from above.

Fig 7: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Position the Engine Support Bridge 10-222A together with the Engine Support Bridge - Engine Bracket 10-222A/1 and the Engine Support Bridge - Spindle 10-222A/11 as shown.

Fig 8: Supporting Engine With Engine Support Bridge

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

Fig 9: Identifying Driveshaft Heat Shield

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Driveshaft Bolted on the Transmission Side:

-- Remove the bolts attaching the driveshaft to the transmission by counterholding with the Counterhold - Multiple Use T10172A and Counterhold - Kit - Adapter 5 T10172/5.

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

-- Secure the driveshaft to the side.

Driveshaft Connected on the Transmission Side:

-- Remove the driveshaft .

Fig 10: Counterholding Driveshaft Using T10172 And T10172/5

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All Vehicles:

-- Remove the bolt -1- for the power steering hydraulic fluid line.

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).

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

Fig 11: Identifying Bolt From Power Steering Line

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-- If equipped, remove the right and left subframe shield -1-. To do so, remove the bolts -arrows- and remove the shield toward the inside.

Fig 12: Identifying Subframe Shield

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-- Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Fig 13: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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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-.

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.

-- Position the Puller - Gear Shaft Linkage T40160 and remove the gearshift lever -1-.

Fig 14: Positioning Puller T40160 And Removing Selector Rod

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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 .

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

Fig 15: Identifying Steering Shaft Universal Joint And Bolt

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-- Remove the lower cover -1- from the transmission in direction of -arrow-.

Fig 16: Identifying Transmission Lower Cover

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-- Insert the guide pin for the Crankshaft Socket T40058 as follows:

Fig 17: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

NOTE:

Ignore -arrow-.

-- Counterhold the crankshaft at the vibration damper using the Crankshaft Socket T40058 to loosen the clutch module bolts on the drive plate.

Fig 18: Identifying TDC With Special Tool Adapter T40058

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-- Remove the six clutch module bolts -arrow- on the drive plate by turning the crankshaft an additional 60° in the direction of engine rotation.

Fig 19: Identifying Clutch Module First Bolt Installation Location

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-- Remove the starter bolt -1- from the engine side.

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

-- Remove the remaining engine/transmission connecting bolts -7 through 11-.

Fig 20: 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 21: Identifying Transmission Holding Fixture

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

Fig 22: Identifying Bolts & Tunnel Crossmember

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-- Lower the transmission only to dimension -a- using the Engine and Gearbox Jack VAS6931.

Fig 23: Lowering Transmission To Dimension -A-

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Dimension -a- = maximum 70 mm.

NOTE:

The illustration shows the installation position with the transmission removed.

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

Fig 24: Drive Axle Heat Shield & Bolts

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

NOTE:

Ignore items -3-.

-- Remove the push rod bolt -2-.

Fig 25: Disconnecting Connector

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Vehicles with Transmission Range Gear Recognition Switch -F208- Through MY 2012

-- Disconnect and free up the connector -1- from the Transmission Range Gear Recognition Switch -F208- using the Reversing Light Switch Connector Release Tool T40138.

Vehicles with Gear Recognition Sensor -G604- from MY 2013.

Fig 26: Identifying Gear Recognition Sensor And Harness Connector

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

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

Fig 27: 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 or -arrow B-, disconnect the connector -2- and free up the wire.

Continuation for All Vehicles

Fig 28: Supporting Engine With Engine Support Bridge

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-- Slightly preload the engine using the Engine Support Bridge - Spindle 10-222A/11.

NOTE:

Use the Step Ladder VAS5085 so that the Engine Support Bridge - Spindle 10-222A/11 can be reached on a raised vehicle.

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