Transmission, removing and installing
WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- On vehicles equipped with Audi Telematics by OnStar ® , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. Refer to .
- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to article and/or Owner's Manual.
- After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar ® , switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module. Refer to .
Special Tools and Equipment
- 10-222A Engine support bridge
- 2024A Engine Sling
- 3282 transmission support
- 3282/12 adjustment plate
- VAG 1383 A Engine/transmission hoist
Removing
WARNING:
Observe safety precautions when disconnecting the battery.
Refer to
- Slide cover over the battery to the right (arrow 1) and pull it off upward (arrow 2).
See Caution before beginning repairs on the electrical system. Refer to Transmission, removing and installing
- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
- Remove rear engine cover (arrows).
- Remove front engine cover (arrows).
- Remove cover -1- in engine compartment (right side).
- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
- Remove hose -4- of crankshaft housing ventilation from air duct -2-.
- Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
- Disconnect hose -1- from air duct.
NOTE:
Illustration depicts air guide with the removed engine from rear.
- Remove engine/transmission connecting bolts accessible from above.
- Position 10-222A engine support bridge on bolted flanges of fenders.
- Remove eyelet for 2024A engine sling.
- Insert bolt -1- in the center bore of 2024A Engine Sling and secure with a cotter pin.
- Attach bolt for 2024A engine sling at 10-222A engine support bridge spindle.
- Attach 2024A Engine Sling to sling clamps at front and rear of engine.
WARNING:
Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
- Slightly pre-tension engine using engine support bridge spindle.
Vehicles with auxiliary heater:
- Remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
All:
- Remove the sound-proofing material (arrows).
- Unbolt bracket for noise insulation panel (arrow).
NOTE:
The flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.
- Disconnect exhaust system at double clamps -arrows-.
- Detach rear part of exhaust system on retaining loops and remove it.
NOTE:
A second technician is required to remove the rear part of exhaust system.
- Remove heat shield for drive axle -arrows-.
- Remove bolts at flange of transmission/drive axle.
- Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
- Secure driveshaft -1- with wire (arrow) to heat shield.
- Remove VAG1359/2 universal mount from VAG1383A engine/transmission jack and place a piece of wood -arrow- onto punch instead.
- Support tunnel cross member using VAG1383A engine/transmission lift.
- First remove bolts -1- and -2-, then bolts -3- and -4-.
- Release slowly the tunnel cross member using VAG1383A engine/transmission hoist.
- Remove nuts -1- and -2-.
- Remove bolts (arrows) and remove tunnel cross member downward using transmission mount.
- Remove left and right heat shields for drive axles (arrows).
- Remove drive axles from transmission drive flange.
NOTE:
Take care not to damage protective coating on drive axles.
Fig 21: Transmission Raised Using Punch Of VAG 1383 A So That A Piece Of Wood Can Be Placed In Between
- Raise transmission using punch of VAG 1383 A engine/transmission hoist high enough, so that a piece of wood (arrow) can be placed in between.
- Remove the three bottom engine/transmission connecting bolts (arrows).
- Lower transmission again.
- Unbolt starter -1- (arrows) and remove it from transmission bell housing.
- Remove remaining mounting bolts for engine/transmission. One bolt remains tightened by hand.
- Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.
Fig 25: Disconnecting Harness Connector From Speedometer Vehicle Speed Sensor (VSS) -G22- At Left Of Transmission
- Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.
- Unbolt heat shield for engine speed (RPM) sensor.
- Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
- Disconnect connecting rod -2- of shift rod.
- Remove pivot rod -1-, to do this unbolt socket-head bolts.
- Remove nut -1- and pull transmission shift lever -2- from shift rod of transmission.
- Set up 3282 transmission support for removing manual transmission 01E all wheel drive using 3282/12 adjustment plate and VAG1383A engine/transmission hoist.
A - Attachments
NOTE:
Courtesy of VOLKSWAGEN UNITED STATES, INC.
- Attachments -A- are shown in schematic form, arrow -B- points in the direction of travel.
- 3282/12 adjustment plate only fits in one position.
- Roll VAG 1383 A engine/transmission hoist underneath transmission. Arrow B (Refer to Illustration Fig 30) on adjustment plate 3282/12 points in the direction of travel.
Fig 32: Align Adjustment Plate 3282/12 Parallel To Transmission And Lock Safety Supports On Transmission
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Remove last mounting bolts for engine/transmission.
- Press transmission off dowel sleeves and lower carefully using VAG 1383 A engine/transmission hoist just enough for access to slave cylinder.
NOTE:
When lowering the transmission, make sure the hydraulic line/hose to clutch slave cylinder is not damaged.
- Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect line.
- Lower transmission completely.
NOTE:
Ensure freedom of movement of drive axles when lowering.
Installing
Installation is reverse of removal, noting the following:
NOTE:
Always replace seals, gaskets and self-locking nuts.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines. remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
- Check clutch release bearing for wear and replace if necessary.
- Coat contact surface of clutch release lever plunger with a thin layer of copper grease, e.g. Z 381 351 TE.
- If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-195-KD1-01.
- 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring.
- If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
- All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid using a tap.
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
- Place intermediate plate onto the dowel sleeves on engine flange.
- Tie electrical wires off to the side before installing, so that they are not pinched between engine and transmission.
- Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow).
- Secure slave cylinder with a new bolt (arrow).
- Install starter and secure connecting bolts for engine/transmission on left and right side.
- Install connecting rods and pivot rods for shift mechanism.
Fig 36: Transmission Raised Using Punch Of VAG 1383 A So That A Piece Of Wood Can Be Placed In Between
- Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise transmission slightly.
- Tighten the three bottom engine/transmission connecting bolts (arrows).
- Lower transmission again.
- Guide the tunnel cross member with loosely inserted transmission mount over front exhaust pipes.
NOTE:
The flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.
- Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise tunnel cross member and transmission slightly.
- Next, tighten bolts -1- to -4- hand-tight.
- Release slowly the VAG 1383 A engine/transmission hoist.
- Tighten bolts for tunnel cross member.
Refer to 40 - FRONT SUSPENSION
Fig 39: Identifying Transmission Raised Using Punch Of VAG 1383 A, A Piece Of Wood And Transmission Mount Bolts
- For tension-free installation, raise transmission using punch of VAG 1383 A engine/transmission hoist high enough so that a piece of wood -1- can be placed in between.
- Tighten bolts (arrows) for transmission mount.
- Slowly lower transmission again.
- Tighten nuts -2- and -3-.
- Bolt drive axles on drive flange.
Refer to 40 - FRONT SUSPENSION
- Secure driveshaft to transmission.
Refer to 39 - FINAL DRIVE, DIFFERENTIAL
- Check adjustment of shift mechanism and adjust if necessary. Refer to Shift lever mechanism, adjusting .
- Install and adjust exhaust system free of stress.
Refer to
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
- Check transmission oil level in manual transmission. Refer to Transmission oil level, checking .
See Caution for disconnecting Telematics battery. Refer to Transmission, removing and installing
- Observe safety precautions after connecting the battery.
Refer to
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
Tightening torques
Securing engine/transmission for manual transmission with All Wheel Drive (with intermediate plate)
| Item no. | Bolt | Nm |
| 1, 10, 11 | M10 x 60 | 45 |
| 2 | M12 x 130 | 65 |
| 3 | M10 x 150 | 45 |
| 4 | M12 x 80 | 65 |
| 5, 6, 8 | M12 x 80 | 65 |
| 7 | M12 x 105 | 65 |
| 9 | M10 x 59 | 45 |
A: Alignment bushing
| Component | Nm | |
| Clutch slave cylinder to transmission | 23 1) | |
| Pivot rod to transmission | 40 | |
| Transmission shift lever to transmission | 23 | |
| Connecting rod for shift rod to transmission | 23 | |
| Engine Speed (RPM) sensor -G28- | 10 | |
| Transmission mount with console to transmission | 23 | |
| Heat shields above drive axles to transmission | 23 | |
| Heat shield for drive axle to cover for Torsen differential | 25 | |
| Bracket for noise insulation to subframe | 10 | |
| Air duct to throttle valve supports | 10 | |
1) Always replace bolt