Transmission, removing

WARNING: This page is about a different car, the 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.

See Caution before beginning repairs on the electrical system. Refer to Transmission, removing and installing

Disconnect battery Ground strap with ignition switched off.

Fig 1: Removing Engine Cover

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Remove engine cover (arrows).

Fig 2: Support Bar 10-222 A With Supports 10-222 A/1 Installed On Engine

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Set up support bar 10-222 A with supports 10-222 A/1.
Pre-tension engine slightly using spindle of support bar.

Fig 3: Removing Sound Insulation

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Remove sound insulation (arrows).

Fig 4: Identifying Heat Shield Fasteners For Torsen Differential

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Remove heat shield for driveshaft from Torsen differential housing (arrows).

Fig 5: Exhaust Pipe Clamp And Driveshaft At Transmission

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Release clamp -1- and remove front part of exhaust pipe -2-.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS

Disconnect driveshaft -3- from transmission and secure at side with wire (see following illustration).

Driveshaft, removing and installing:

Refer to 39 FINAL DRIVE, DIFFERENTIAL

Fig 6: Drive Shaft Secured With Wire And Locating Speed Nut

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Re-insert speed nut (arrow) slightly and secure drive shaft with wire.

Fig 7: Removing Noise Insulation Bracket

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Remove bracket for sound insulation (arrow).

Fig 8: Three Lower Engine And Transmission Connecting Bolts

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Remove three engine/transmission connecting bolts underneath (arrow).

Fig 9: Detaching Heat Shields And Right-Hand Axle Shaft

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Remove heat shields (arrow -1- and arrow -2-) above right drive axle.

Fig 10: Drive Shafts And Flange Shafts

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Disconnect drive axles -1- from drive flanges and tie up out of way.

NOTE: Take care not to damage surface protection of drive axles.

Support transmission slightly with engine/transmission lifter V.A.G 1383 A.

Fig 11: Drive Shafts And Flange Shafts

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Remove bolts -2-, then bolts -3- on tunnel crossmember.
Remove two nuts -4- and remove tunnel crossmember.
Lower engine/transmission lifter V.A.G 1383 A and place to one side.

Fig 12: Identifying Transmission Shift And Pivot Rods

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Disconnect selector rod (arrow A-).
Remove hex socket head bolt of push rod (arrow -B-).

Fig 13: Identifying Connectors For Vehicle Speed Sensor (VSS) And Back-Up Lights

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Disconnect connector from speedometer vehicle speed sensor (arrow -A-).
Disconnect connector from back-up light switch (multi-function sensor, arrow B-).
Disconnect all other electrical connections and Ground wires from transmission and from engine/transmission connecting bolts.

Fig 14: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing

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If installed, remove Engine speed (RPM) sensor -G28- from left of transmission (arrow) and place to one side.

Fig 15: Removing Starter Bolt

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Disconnect engine/transmission starter and secure against inadvertent operation if necessary.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

NOTE: There is no need to disconnect starter cables.

Fig 16: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed

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Remove engine/transmission connecting bolts underneath with exception of bolts (arrow -A- and arrow -B-).

Fig 17: Transmission Support 3282 Attachment Plate

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To remove manual transmission 012, align transmission support 3282 using adjustment plate 3282/10 and position on transmission lifter V.A.G 1383 A.

A - Support elements

NOTE:

Drawing shows only symbolic representation of support elements -A-. Arrow -B- points in direction of travel.
Adjustment plate 3282/10 only fits in one position.

Fig 18: Setting Transmission Jack Under Vehicle

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Position transmission jack under vehicle with arrow symbol -B- (Refer to Fig 17) on adjustment plate pointing in direction of travel/vehicle.

Fig 19: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Support On Transmission

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Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.

Fig 20: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed

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Remove remaining engine/transmission connecting bolts (arrows -A- and -B-).
Press transmission out of dowel sleeves and carefully lower slightly using transmission lifter V.A.G 1383 A until slave cylinder is just about accessible.

NOTE: When lowering transmission take care not to damage hydraulic pipe to slave cylinder.

Fig 21: Identifying Clutch Slave Cylinder Bracket And Fastener

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Remove clutch slave cylinder (arrow) and secure with wire, do not open hydraulic circuit.

NOTE: Do not press clutch pedal once slave cylinder has been removed.

Lower transmission completely.

NOTE: When lowering ensure clearance from drive axles.

Fig 22: Transmission Mount

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If removed transmission is to be replaced, first modify transmission mount to suit replacement transmission (arrows).

For repairs, secure transmission to repair stand by means of transmission support VW 353 and retaining plate VW 309.