Transmission, Disassembling

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.

-- Place the Shop Crane - Drip Tray VAS6208 underneath.

Fig 1: Locating Transmission Fluid Drain Plug

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-- Remove the plug -arrow- and drain the transmission fluid.

-- Secure the Gearbox Support T40206 to the transmission with the bolts -arrows- and tighten it in the assembly stand.

Fig 2: Securing T40206 To Transmission

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-- Remove the clutch module. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

-- Carefully set down the clutch module, for example, on a workbench.

-- Remove the clutch release lever -1- together with the release bearing -2- and the spring -3-.

Fig 3: Identifying Clutch Release Lever Components

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-- Remove the bolts -4-, the locking plate -5- (if equipped) and the guide sleeve -6-.

-- If equipped, remove the Transmission Neutral Position Sensor -G701- -A-.

Fig 4: Removing/Installing Transmission Neutral Position Sensor

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-- Remove the bolt -arrow- and remove the sensor from the cover -B-.

NOTE:

The cover -B- remains installed.

If a cap is installed in place of the Transmission Neutral Position Sensor -G701-, the closure cap does not need to be removed when disassembling and assembling the transmission.

-- Remove the Selector Shaft Guide Pins T40216 on the gearshift shaft.

Fig 5: Using Selector Shaft Guide Pin T40216

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-- Remove the bolts -1- and pry the selector shaft cover -2- off carefully.

Fig 6: Removing/Installing Selector Shaft Cover

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-- Lift the gearshift shaft -arrow A- and remove it -arrow B-.

Fig 7: Removing Gearshift Shaft

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-- Counterhold the in- and output shafts by sliding the selector rods -1- through -4- in the direction of -arrow-.

Fig 8: Counterhold Output Shafts By Sliding Selector Rods

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NOTE:

Insert a rag into the gearshift shaft opening between the tool and the housing wall to prevent damaging the transmission cover.

-- Push the cover -A- for the output shaft in the center and pry it out in direction of -arrow-.

Fig 9: Push Cover -A- For Output Shaft In Center And Pry It Out In Direction Of -Arrow-

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-- Now remove the bolt from the output shaft -A-.

Fig 10: Removing Bolt From Output Shaft

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B - Allen key 12 mm

C - Torque wrench

-- Then shift gearshift rails into neutral position.

-- Pry out the input shaft seal.

Fig 11: Removing Input Shaft Seal

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-- The locking ring -1- in front of the input shaft ball bearing must then be removed.

Fig 12: Identifying Shim -2- And Input Shaft Locking Ring -1-

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-- Remove the shim -2-.

NOTE:

If it is not possible to remove the locking ring -1-, then remove the center differential's transmission cover first and then move the input shaft forward using a rubber hammer.

The shim -2- must definitely be removed before pressing out the shift shaft package so that it does not slide into the locking ring groove.

-- Remove the bolts -A- and -arrows- that attach the center differential housing -B- to the transmission cover.

Fig 13: Locating Center Differential Housing Bolts

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-- Carefully remove the center differential housing -6-, the pressure spring -3-, the adjusting shim -4- and the plate spring -5-.

Fig 14: Identifying Differential Housing -6-, Pressure Spring -3-, Adjusting Shim -4- & Plate Spring -5-

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-- Remove the center differential -2- and the gear carrier -1-.

If the gear carrier -1- remains in the center differential housing, proceed as follows:

Fig 15: Center Differential Housing, Proceed As Follows

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-- Hold the gear carrier -1- by one of the side ribs with pliers and remove it in direction of -arrow A-.

-- Using a Rubber Hammer, tap the housing on alternating sides -B arrows-.

CAUTION:

Do not damage sealing surfaces when doing so.

-- Remove the locking ring -1- and pull off the output wheel/drive wheel -2- from the pinion.

Fig 16: Identifying Output Components

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-- Remove the spacer sleeve -3- and impeller wheel/drive gear -4- from the output shaft. Remove the impeller wheel/drive gear's needle bearing at the same time.

-- Then turn transmission in assembly bracket so transmission cover -D- faces upward.

Fig 17: Identifying Transmission Cover Bolts

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-- Remove the following bolts: -A- (used for mounting the bearing bracket), bolt -B- (for mounting the reverse shaft) and bolt -C- (for the transmission cover) -D- on the transmission housing -E-.

-- Remove the transmission cover -D-, while being careful of the ball bearing on the input shaft (do not tilt the transmission cover when removing it).

NOTE:

The ball bearing that is located at the back of the input shaft has a sliding fit in the transmission cover.

-- Remove the reverse wheel with reverse shaft -1-.

Fig 18: Identifying Transmission Housing Components

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-- Remove the oil catch tray -2- from the bearing bracket -3- -Arrows A- and -Arrow B-.

-- Remove the magnet -4- and the oil guide element -5- from the transmission housing.

-- Secure the Gearbox Assembly Tool T40213 to the Gearbox Support T40206 using the bolts -arrows-.

Fig 19: Attaching Gearbox Assembly Tool T40213 To Gearbox Support T40206

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CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be removed together.
It is permissible to remove the shaft alternating from side to side by turning each spindle maximum one turn.
Pay special attention to synchronizing the reverse gear when removing the shift shaft package. It must not slide off of the output shaft!

-- Remove the input and output shafts from the ball bearings inside the transmission housing by turning the Spindles on the Gearbox Assembly Tool T40213 and alternating from side to side every other turn. Make sure the shift shaft package does not get dropped (get another technician to help you).

-- Remove the in- and output shaft and the shift fork group from the transmission housing.