Transmission, removing from vehicles with 6-cylinder engine

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Transmission, Removing From Vehicles

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Special tools, testers and auxiliary items required

Engine support bridge 10-222 A
Transmission support 3282
Adjustment plate 3282/43
Torque wrench V.A.G 1331

Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A

Special tools, testers and auxiliary items required

Fig 2: Engine Sling 2024 A

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Engine sling 2024 A
Grease for clutch plate splines G000100
Copper grease Z381351TE

Procedure

NOTE:

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

CAUTION: Follow steps required when disconnecting battery →

Fig 3: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect battery Ground (GND) strap - arrow -.

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: Removing Coolant Hoses

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Unfasten coolant expansion tank - arrow -.
Disconnect electrical connector for Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank. Move coolant expansion tank (with coolant hoses - 1to 3 - attached) clear to one side.

Fig 8: Removing Cover In Engine Compartment (Right Side)

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

Fig 9: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct

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Remove bolts - arrows - from solenoid valve mounting plate - 3 -.
Disconnect air intake hose - 1 - from mass air flow sensor.
Pull hose - 4 - for crankcase breather system off air duct - 2 -.

Fig 10: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module

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Loosen bolt - arrow - and disconnect air duct - 2 - from throttle valve module.
If installed, disconnect hose - 1 - from air duct.

NOTE:

In the illustration, the air duct is shown from the rear and with the engine removed.

Remove engine/transmission securing bolts which are accessible from above.

Fig 11: Removing Harness Connectors From Bracket At Left Of Bulkhead

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Disconnect connectors - 1 to 4 - from retainer at left of bulkhead.
Disconnect electrical connectors - 1 - and - 4 -.
Move oxygen sensor wires clear.
Remove retainer for connectors.

Fig 12: Left Front Exhaust Pipe To Exhaust Manifold Nuts

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Remove nut - 1 - (access from above), connecting left front exhaust pipe with exhaust manifold.

NOTE:

In the illustration the engine has been removed.

Fig 13: Placing Insert Pad For Front Fender T40045 On Both Sides Between Fender Attachment Edge And Web Plate Lying Beneath

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Detach rubber seal from edges of wing mounting flanges.
To avoid damaging edges of fenders use Engine support bridge 10-222 A, insert insert pad for front fender T40045 on both sides between the fender mounting flange and body panel underneath.

Fig 14: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders

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Set up Engine support bridge 10-222 A on fender mounting flanges.

Fig 15: Removing Eyelet For 2024A Engine Sling

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Remove eye of lifting tackle 2024A.
Re-insert pin - 1 - in middle hole on lifting tackle and secure it with split pin.
Hook pin on lifting tackle 2024A onto spindle on Engine support bridge 10-222 A.
Hook lifting tackle 2024A into lifting eyes at front and rear of engine.

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

Slightly pretension engine with spindle of Engine support bridge.

Fig 16: Fasteners

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On vehicles installed with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary/additional heater to sound insulation.

Fig 17: Front And Rear Sound Insulation And Fasteners

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Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
If installed, loosen quick-release fasteners - 3 - and remove rear sound insulation - B -.

Fig 18: Removing Noise Insulation Bracket

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Remove bracket - arrow - for sound insulation.

Fig 19: Drive Axle Heat Shield

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Remove heat shield - arrow - for drive axles (left and right).

Fig 20: Removing Bolts For Front Vehicle Floor Crossmember

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If installed, remove tunnel cross member (front) - 1 to 4 -.

Fig 21: Exhaust System And Clamps

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Disconnect exhaust system at clamps - arrows -.
Remove front exhaust pipe (left-side) with catalytic converter → 3.0 Liter 6-Cyl. 5V Engine Mechanical, Engine Code(s): AVK - 26 EXHAUST SYSTEM, EMISSION CONTROLS .
Remove bracket for exhaust pipe (front right) from transmission.

Fig 22: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

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

Fig 23: Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link

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If installed, unclip operating rod for Left Front Level Control System Sensor G78 from lower transverse link - arrow -.

Fig 24: Checking Holes Align Using Testing Mandrel 3393

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Before loosening subframe, use testing mandrel 3393 to check whether holes - 1 - and - 2 - are aligned.

If holes are not aligned, a wheel alignment has to be performed after installing the subframe.

Fig 25: Removing Front Bolts From Left And Right Subframe

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

Fig 26: Three Lower Engine And Transmission Connecting Bolts

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Remove lower engine/transmission securing bolts - arrows -.

Fig 27: Removing Front Bolts From Left And Right Subframe

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Temporarily secure subframe again.

Temporary tightening torque:

1 - approx. 100 Nm

2 - approx. 70 Nm

3 - approx. 70 Nm

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

Fig 28: Drive Shafts And Flange Shafts

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Remove drive axles - 1 - from flange shafts and tie up to side.

NOTE:

Do not damage surface coating on drive axles.

Support transmission with engine/transmission jack V.A.G 1383 A.
Remove bolts - 2 - and then bolts - 3 - at tunnel cross member.
Remove two nuts - 4 - and detach tunnel cross member.
Carefully lower engine/transmission jack V.A.G 1383 A and move it aside.

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

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Remove connecting rod - 2 - for selector rod.
Disconnect push rod - 1 - ; by removing hex socket-head bolt.

Fig 30: Back-Up Light Switch Connector

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Disconnect connector - arrow - for back-up light switch on right side of transmission.

Fig 31: Selector Shaft Lever Nut

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Remove nut - arrow - and detach selector shaft lever from selector shaft.

Fig 32: Locating Cable Ties And Oxygen Sensor Wiring At Side

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Open cable ties - arrows A and B - , unclip oxygen sensor wiring at side - arrows C - and move wiring clear.

Fig 33: Locating Starter Bolt

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Detach starter from engine/transmission and secure if necessary →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

NOTE:

Starter cables do not have to be disconnected.

Fig 34: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing

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If installed, remove engine speed (RPM) sensor G28 from left side of transmission - arrow - and lay aside.

Fig 35: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed

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Remove upper engine/transmission securing bolts as well as those on the side, except for bolts marked with - arrow A - and - arrow B -.

Fig 36: Support Elements 3282/49 And 3282/52 And Arrow On The Adjustment Plate

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To remove manual transmission 01X set up transmission support 3282 with adjustment plate 3282 /43 and place on engine/transmission jack V.A.G 1383 A.

NOTE:

The adjustment plate 3282/49 - arrows A - and 3282/52 - arrows B - are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points toward the direction of travel.
Adjustment plate can only be installed in one position.

Fig 37: Supporting Elements Secured To Left Side Of Transmission

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Align adjustment plate parallel to transmission.
Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt - arrow - on right side to 20 Nm.

Fig 38: Supporting Elements Secured To Right Side Of Transmission

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Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt - arrow - on left side to 20 Nm.

Fig 39: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed

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Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.
Press transmission off dowel sleeves and lower carefully using engine/transmission jack V.A.G 1383 A just far enough to gain access to slave cylinder.

NOTE:

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

Fig 40: Slave Cylinder Bracket And Fastener

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Remove slave cylinder from transmission - arrow - and secure with wire; do not open line/hose 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.

NOTE:

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

Before carrying out assembly work, secure transmission to assembly stand, using holding fixture VW 540 → Transmission, mounting on assembly stand .

Fig 41: Transmission Mounting

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

Installing transmission → Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine .