Transmission, Removing, 4.2L FSI 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.

CAUTION:

Removing the transmission on an Audi A5 with a 4.2L FSI engine

The Audi A5 transmission with the 4.2L FSI engine through VIN 8T-8A-023117 can only be removed together with the engine. .

Special tools and workshop equipment required

Counterhold - Multiple Use T10172A with Counterhold - Kit - Adapters 5-9 T10172/5
Reversing Light Switch Connector Release Tool T40138
Puller - Gear Shaft Linkage T40160
Gearbox Support T40173
Socket and Jointed Extension - 12mm T40220
Engine and Gearbox Jack VAS6931
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 Cover

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-- Only loosen the wheel bolts for the front wheels. Do not remove the wheels.

-- Raise the vehicle.

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

Fig 3: Identifying Noise Insulation Components

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

Fig 4: Identifying Subframe Crossbrace

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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.

-- Remove the nuts -arrows- on the left front muffler.

Fig 5: Identifying Left Front Muffler Nuts

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-- Remove the nuts -arrows- on the right front muffler.

Fig 6: Identifying Right Front Muffler Nuts

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Fig 7: Identifying Bolts - Vehicles With Dual Exhaust System

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CAUTION:

The coupling elements in the front muffler could be damaged.

Do not bend decoupling element in front muffler more than 10°.

-- Loosen the clamping sleeves -1- and -2-, slide them toward the rear and remove the left and right front mufflers.

-- Disconnect the connector -1- from the steering gear and connector -2- from the Engine Speed Sensor -G28- and free up the wires.

Fig 8: Disconnect Connector From Servotronic Solenoid Valve

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

Fig 9: Identifying Transmission Lower Cover

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Move into 6th gear by removing the gearshift shaft -1- and shifting the gearshift lever -2- forward in direction of -arrow-.

Fig 10: Identifying Gearshift Assembly
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Block the driveshaft using the Counterhold - Multiple Use T10172A and Counterhold - Kit - Adapters 5-9 T10172/5 so it will not turn.

Fig 11: Counterholding Driveshaft Using T10172 And T10172/5

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-- Remove the six bolts -arrow- for the drive plate. To do this, turn the clutch module an additional 60° in the engine direction of rotation via the front wheels.

Fig 12: Identifying Clutch Module First Bolt Installation Location

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-- Remove the front wheels.

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

Fig 13: Driveshaft Cover -1-

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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 14: Identifying Subframe Shield

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-- Remove the nuts -arrows- and the bolt -1- and push the catalytic converter to the right side.

Fig 15: Identifying Nuts And Bolt, Removal

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NOTE:

The illustration shows the installation position with the engine removed.

Use the Socket and Jointed Extension - 12mm T40220 for loosening the nuts -arrow- and the right catalytic converter -A- from the exhaust manifold.

Fig 16: Using T40220 To Loosen Nuts

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Secure the right catalytic converter loosely using a nut so it does not fall down.

-- Remove the rear coolant pipe .

-- Remove the air duct -arrow-.

Fig 17: Identifying Air Duct

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-- Disconnect the connector -1- on the Mass Airflow Sensor -G70-.

-- Remove the vacuum line -3- to the air guide pipe.

Fig 18: Disconnecting Connector On Mass Airflow (MAF) Sensor

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CAUTION:

There is a risk of violating emissions regulations on USA vehicles.

Do not open the hose connection -2- !

-- Move the air guide hose with the attached crankcase ventilation hose -2- to the side by loosening the hose clamps -4- and opening the clips -arrows-.

Fig 19: Identifying Secondary Air System Components

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-- Disconnect the vacuum line -1-.

-- Remove the air filter lower section and disconnect the connector -2- from the Intake Air Switch-Over Valve -N335- on the back.

-- Disconnect the hose -3- to the secondary air injection pump.

-- Remove the coolant hose from the radiator -2- and from the right coolant pipe -1-.

Fig 20: Identifying Coolant Hose From Radiator And Right Coolant Pipe, Removal

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-- Remove the bolts -1- and -2- and the coolant hose -arrow-.

Fig 21: Identifying Bolts And Coolant Hose, Removal

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-- Remove the right coolant pipe from the connection and lay it aside.

NOTE:

Ignore -arrow-.

-- Remove the bolts -1- and -2- and the coolant connection.

Fig 22: Identifying Bolts And Coolant Connection, Removal

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

Fig 23: Removing/Installing Connecting Rod Bolt -2-

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NOTE:

Ignore item -1-.

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

Fig 24: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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

Fig 25: 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.

Fig 26: Counterholding Driveshaft Using T10172 And T10172/5

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Driveshaft Connected on the Transmission Side:

-- Remove the driveshaft .

All Vehicles:

Fig 27: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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-- Remove the bolt -2- and 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-.

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 28: 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 .

Fig 29: Locating Universal Joint Bolt

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

-- Remove the bolt -1- press the retaining tab off the transmission and tilt it back in direction of -arrow-.

Fig 30: Identifying Bolt, Removal

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-- Remove the starter bolt -1-.

Fig 31: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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

-- Remove the rest of the bolts -7 through 11- connecting the engine to the transmission.

-- 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 32: Identifying Transmission Holding Fixture

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

Fig 33: Identifying Bolts & Tunnel Crossmember

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

Fig 34: Lowering Transmission To Dimension -A-

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Dimension -a- = maximum 100 mm.

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

Fig 35: Drive Axle Heat Shield & Bolts

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove the bolts -arrows- and the left drive axle heat shield.

Fig 36: Identifying Bolts And Left Drive Axle Heat Shield

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NOTE:

The illustration shows the installation position with the transmission removed.

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

Fig 37: Identifying Left And Right Drive Axles

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

NOTE:

Ignore item -3-.

-- Remove the push rod bolt -2-.

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

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

Fig 38: Disconnecting Connector

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Right and left bracket -1- for the exhaust system .

Fig 39: Attaching Exhaust System Retaining Strap Bracket To New Transmission
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Tunnel crossmember with the transmission mount and transmission support. Refer to OVERVIEW - SUBFRAME MOUNT .
If necessary remove the clutch module .

Fig 40: Removing/Installing Flywheel Components
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