Removing transmission on vehicles with 4.2 Liter V8 engine (S4)

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2007 Audi S4, 2007 Audi RS 4, and 2006 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Removing Transmission On Vehicles With 4.2 Liter V8 Engine (S4)

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Special tools, testers and auxiliary items required

Support bracket 10 - 222 A
Shackle 10 - 222 A/12
Lifting tackle 2024 A
Hose clamps, up to Ø 25 mm 3094

Transmission support 3282
Adjustment plate 3282/38

Special tools, testers and auxiliary items required

Fig 2: Locating Pins 3393

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Locating pins 3393

Fig 3: Identifying Engine/Transmission Jack V.A.G. 1383 A

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Engine and transmission jack V.A.G 1383 A

Removing

NOTE:

All cable ties which are released or cut open during removal must be installed in the same position when installing.
Heat insulation sleeves removed during removal of transmission must be installed in the same position when installing.

CAUTION:

Follow steps required when disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

With the ignition switched off, disconnect battery ground (GND) strap.

Fig 4: Removing Rear Engine Cover

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Pull off rear engine cover - arrows -.

Fig 5: Removing Front Engine Cover

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Pull off front engine cover - arrows -.

Fig 6: Removing Cover In Engine Compartment (Left Side)

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Remove cover - 1 - on left side of engine compartment.

Fig 7: Coolant Expansion Tank, Bolts And Coolant Hose

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Clamp off coolant hose - 1 - with hose clamp 3094 and disconnect hose at coolant expansion tank.
Unbolt coolant expansion tank - 2 - - arrows -.
Disconnect electrical wire leading to Engine Coolant Level (ECL) Warning Switch F66 at expansion tank (bottom) and move coolant expansion tank (with coolant hose - 3 - attached) clear to one side.
If necessary, close off the connection with a suitable plug.

Fig 8: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead

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Disconnect electrical connectors - 1 to 4 - from retainer at left of bulkhead.
Disconnect electrical connectors - 1 - , - 3 - and - 4 -.
Disconnect retainer at bulkhead.
Disconnect heat insulation sleeve at wiring harness and move wiring harness clear.

Move oxygen sensor probe wires clear (downwards).

Fig 9: Removing Cover In Engine Compartment (Right Side)

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Remove cover - 1 - on right side of engine compartment.

Fig 10: Removing Air Guide Hose

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Remove air intake hose - arrows -.

Fig 11: Removing Bracket For Electrical Harness Connectors At Right From Bulkhead

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Disconnect connectors - 1 to 4 - from retainer at right of bulkhead.
Disconnect electrical connectors - 2 - and - 4 -.
Move oxygen sensor probe wires clear (downwards).

Fig 12: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet

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Fix a shackle 10 - 222 A/12 to engine lifting eye (rear right).

NOTE:

- Item 1 - can be disregarded.

Fig 13: Support Bracket 10 - 222 A Set Up On Wing Mounting Flanges

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Set up support bracket 10 - 222 A on wing mounting flanges.

Fig 14: Support Hooks And Locking Pins On Lifting Tackle Secured With Retainers And Pin In Lifting Tackle Center Hole

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Remove eye of lifting tackle 2024 A.
Re-insert pin - 1 - in center hole of lifting tackle and secure with split pin.
Hook pin on lifting tackle 2024 A onto spindle of support bracket 10 - 222 A.
Hook lifting tackle 2024 A into lifting eye at front of engine and into shackle 10 - 222 A/12 at rear.

CAUTION: Support hooks and locking pins on lifting tackle must be secured with retainers - arrows - in illustration.

Take up weight of engine on spindle of support bracket, but do not lift.

Fig 15: Fasteners

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Unbolt both front wheels.
On vehicles installed with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary/additional heater to noise insulation.

Fig 16: Removing Quick-Release Fasteners, Screws And Noise Insulation

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Release quick release fasteners - 1 - , unscrew bolts - 2 - and remove noise insulation.

Fig 17: Removing Bracket For Noise Insulation

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Unbolt bracket for noise insulation - arrows -.

Fig 18: Removing Wiring Harness Bracket At Right Engine Plate

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Unbolt bracket for wiring harness at engine support (right-side) - arrows -.

Fig 19: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

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Unscrew nuts - 1 - at bottom of engine mountings (left and right).

Fig 20: Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link

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If installed, unclip operating rod for vehicle level sender from lower transverse link - arrow -.

Fig 21: Checking Holes Align Using Testing Mandrel 3393

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Before slackening subframe mountings, use locating pins 3393 to check whether holes - 1...3 - are aligned.

CAUTION: If this is not the case, wheel alignment has to be performed after installing the subframe.

Fig 22: Removing Front Bolts From Left And Right Subframe

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First remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
Lower subframe at the front.

Fig 23: Removing/Installing Bottom Engine/Transmission Connecting Bolts

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Unscrew lower engine/transmission securing bolts - arrows -.

Fig 24: Removing Front Bolts From Left And Right Subframe

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Temporarily secure subframe again. Temporary tightening torque:

approx. 100 Nm
approx. 70 Nm
approx. 70 Nm

CAUTION: Do not replace bolts yet or tighten to their final torque. This will be done when installing the transmission.

Fig 25: Locating Clamping Sleeves

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NOTE:

The flexible exhaust pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Disconnect exhaust system at clamps - arrows -.

Fig 26: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of Wood

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Remove universal mounting V.A.G1359/2 from engine and transmission jack V.A.G 1383 A and place a wooden block - arrow - on the lifting column in its place.
Support the rear cross member with engine and transmission jack V.A.G 1383 A.
First unscrew bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.

Fig 27: Identifying Distance Between Cross Member And Body Reaches Dimension

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Slowly lower rear cross member with engine and transmission jack V.A.G 1383 A.

NOTE:

Do not lower the transmission too far: the distance between the rear cross member and the body (dimension - x -) must not be more than 60mm. Otherwise, the driveshaft joint and the flexible joint in the front exhaust pipe could be damaged. If necessary, tighten spindle of support bracket 10 - 222 A so that dimension - x - is not exceeded.

Fig 28: Drive Axle Heat Shield

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Remove heat shields - arrow - for drive shafts (left and right).
Unbolt drive shafts from transmission flanges.

NOTE:

Make sure you do not damage surface coating on drive shafts.

Fig 29: Identifying Push Rod And Connecting Rod For Selector Rod

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Unscrew connecting rod - 2 - for selector rod.
Disconnect push rod - 1 - ; to do so, unscrew hexagon socket head bolt.

Fig 30: Freeing Up Oxygen Sensor Wires At Areas Indicated By On Transmission

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Disconnect oxygen sensor probe wiring on transmission at the points marked with - arrows -.

NOTE:

In the illustration the engine/transmission assembly has been removed.

Fig 31: Removing Bolt At Strap For Left Front Exhaust Pipe

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Unscrew bolt - arrow - at bracket for front exhaust pipe (left-side).

Fig 32: Removing/Installing Nuts For Left Front Exhaust Pipe/Exhaust Manifold

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Unscrew nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.

NOTE:

In the illustration the engine has been removed.

Disconnect front exhaust pipe from exhaust manifold (left-side).
Remove front exhaust pipe.

Fig 33: Removing Bolt At Strap For Right Front Exhaust Pipe

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Unscrew bolt - arrow - at bracket for front exhaust pipe (right-side).

Fig 34: Removing Nuts For Right Front Exhaust Pipe/Exhaust Manifold

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Unscrew nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.

NOTE:

In the illustration the engine has been removed.

Remove front exhaust pipe.

Fig 35: Identifying Driveshaft Shield

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Unbolt heat shield for driveshaft - arrows -.
Unscrew bolts at transmission/driveshaft flange.
Slide driveshaft together towards rear final drive. The constant velocity joints can be moved axially.
Allow driveshaft to rest on rear section of exhaust system.

Fig 36: Tunnel Cross Member Nuts

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Unscrew two nuts - arrows - and Disconnect tunnel cross member.

Fig 37: Identifying Selector Mechanism Fasteners

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Unscrew nut - 1 - and pull transmission selector lever - 2 - off transmission selector shaft.

Fig 38: Disconnecting Harness Connector For Back-Up Light Switch At Right Of Transmission

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Disconnect connector - arrow - for reversing light switch on right side of transmission and move wiring clear.

Fig 39: Starter And Mounting Bolts

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Unbolt starter - 1 - - arrows - and pull it away from bell housing.
Remove remaining engine/transmission bolts. Leave 2 bolts screwed in hand-tight.

Fig 40: Bracket For Front Exhaust Pipe (Left-Side) On Transmission

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Unbolt bracket for front exhaust pipe (left-side) on transmission - arrows -.

Fig 41: Hole In Supporting Elements Of Transmission Support 3282

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Drill a hole of 10.2mm - arrow - in supporting element of transmission support 3282.

Fig 42: Transmission Support 3282 With Adjustment Plate 3282/38 For Removing Manual Transmission 03A (All Wheel Drive) And Place On Engine And Transmission Jack V.A.G 1383 A.

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Set up transmission support 3282 with adjustment plate 3282/38 for removing manual transmission 03A (All wheel drive) and place on engine and transmission jack V.A.G 1383 A.

NOTE:

The positions of the support elements - arrows - are shown on the adjustment plate in schematic form (the arrow points in direction of travel).
The adjustment plate can only be installed in one position.

Fig 43: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Left Side Of Transmission

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Align adjustment plate parallel to transmission and secure support elements - arrows - to left side of transmission.

Fig 44: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Right Side Of Transmission

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Align adjustment plate parallel to transmission and secure support elements - arrows - to right side of transmission.
Remove 2 last engine/transmission bolts.
Press transmission off dowel sleeves and lower carefully with engine and transmission jack V.A.G 1383 A just far enough to gain access to the clutch slave cylinder.

NOTE:

When lowering transmission, ensure hydraulic line to clutch slave cylinder is not damaged.

Fig 45: Slave Cylinder Bracket And Fastener

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Remove clutch slave cylinder - arrow - and secure with wire; do not open hydraulic system.

CAUTION: Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

Lower transmission completely.

NOTE:

When lowering transmission, make sure there is sufficient clearance to drive shafts.

Fig 46: Identifying Transmission Mounting Is Transferred To New Transmission

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If you will be installing a new transmission instead of the one removed, the transmission mounting has to be transferred to the new transmission - arrows -.

Installing transmission → Installing transmission on vehicles with 4.2 Liter V8 engine (S4) .