Transmission, Removing
Special tools and workshop equipment required
- Engine Support Bridge 10-222A
- Pry Lever 80-200
- Engine and Gearbox Jack VAS6931
- Used Oil Collection and Extraction Unit SMN372500
- Engine Bung Set VAS6122
- Counterhold - Multiple Use T10172A with Counterhold - Kit - Adapter T10172/5
- Hose Clamps - Up To 25mm 3094
- Counterhold - Vibration Damper T10355
- Gearbox Support T40173
Before using the Gearbox Support T40173 always check if it meets the requirements.
The older version mounts, should not be used and should be replaced.
Characteristics (Newer Version)
On the newer version the components illustrated -red- are -yellow - chrome plated.
If the mount does not comply with corresponding specifications, proceed as follows:
- Contact your tool supplier for an exchange.
Preparing the Gearbox Support T40173:
-- The bracket -1- must be turned so that the shorter side faces up as illustrated.
-- The bracket -2- must be turned so that the longer side faces up as illustrated.
-- The bracket -3- must be turned so that the shorter side faces up as illustrated.
Transmission, Removing
Follow all safety precautions, refer to SAFETY PRECAUTIONS .
- The electro-mechanical parking brake is opened
- Move the selector lever into "D/S".
-- Position the front wheels so they are straight.
De-Energizing the High Voltage System
Follow the High Voltage System General Warnings, refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
Turning off the voltage in the high voltage system is carried out exclusively via the Guided Fault Finding on the Vehicle Diagnostic Tester.
Extremely dangerous high voltage
Electrocution can cause death or very serious personal injury.
- The high voltage system may only be turned off by a qualified person (Audi high voltage technician).
- It must be certain that the voltage for the high voltage system is turned off. The voltage is guaranteed to be off exclusively with the Vehicle Diagnostic Tester via the "Guided Fault Finding ".
- The qualified technician (Audi high voltage technician) will make sure the voltage is turned off and that the system cannot turn back on again using a Service Disconnect Lock T40262. The qualified technician should make sure the system cannot turn on again by keeping the key and the High Voltage System Maintenance Connector -TW- in a safe place.
- The qualified personnel (Audi high voltage technicians) mark the vehicle with a label.
De-energizing the high voltage system:
Connect the Vehicle Diagnostic Tester
Select the Guided Fault Finding mode
Using the Go To button, move through the following menu points
Function/Component Selection
Body
Electrical Equipment
OBD-Capable System
8C - Hybrid Battery Management -J840
8C - Hybrid Battery Management, Functions
51 - De-Energize The High Voltage
-- Remove the engine cover in direction of -arrows-.
-- Loosen the left and right front wheel bolts.
-- Lift the vehicle.
-- Remove the left and right front wheels.
-- Remove the noise insulations -1 and 2-, refer to OVERVIEW - NOISE INSULATION .
-- Remove the rear muffler with the center muffler, refer to OVERVIEW - MUFFLER .
-- Remove the bolts -arrows- and remove the driveshaft heat shield -1-.
-- Remove the driveshaft, refer to DRIVESHAFT, REMOVING AND INSTALLING .
-- Remove the front muffler, refer to FRONT MUFFLER, REMOVING AND INSTALLING, NON-HYBRID VEHICLES or FRONT MUFFLER, REMOVING AND INSTALLING HYBRID VEHICLES .
-- Disconnect the cable from the crossbraces -1 and 2-.
The suspension components could be damaged.
Do not rest the vehicle on its wheels if the subframe, the steering gear or the subframe crossbrace are not installed correctly.
Do not support the vehicle on the subframe or on the subframe crossbrace (for example using a floor jack or something similar)!
-- Remove the bolts -arrows- and remove the subframe crossbrace.
-- Remove the drive axle noise insulation -1- inside the right and left wheel housing.
-- Remove the bolts -arrows- and remove the heat shield from the right drive axle.
The illustration shows the installation position with the transmission removed.
-- Remove the right subframe shield under the right drive axle, refer to SUBFRAME HEAT SHIELD, REMOVING AND INSTALLING .
-- Remove left and right drive axles from transmission flange shafts.
-- Remove the bolt -3- and the potential equalization cable -2- from the transmission.
The airbag spiral spring could be damaged.
- Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
- Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.
-- Remove the bolt -arrow- for the universal joint, refer to OVERVIEW - STEERING COLUMN .
-- Remove the steering intermediate shaft -1- from the steering gear -2-.
-- Loosen the fuse and press the locking mechanism downward in order to disconnect the connector -1- for the vehicle signal (CAN-Bus and terminal 15) on the Power Steering Control Module -J500-.
-- Loosen the retainer in direction of -arrow-, push the release downward and disconnect the connector -2- for terminal 30 power supply from the Power Steering Control Module -J500-.
-- Remove the connector -A- for the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- from the right side of the transmission.
-- Next, unclip the wire from the transmission -arrows- and tie it off to the side.
-- Disconnect the connector -A- to the Drive Motor High Voltage Wiring Harness -PX2- and the connector -B- from the Drive Motor Rotor Position Sensor 1 -G713- on the top of the transmission on the left side.
-- Disconnect the connector -C- from the Oxygen Sensor After Three Way Catalytic Converter -G130- and remove the cable tie -arrow-.
Remove the Drive Motor High Voltage Wiring Harness -PX2- as follows from the Electro-Drive Drive Motor -V141- on the transmission:
-- Make sure that the red warning label is not damaged.
Handling the high voltage cables:
- Do not stand on or place tools on the high voltage cables or their components. This may damage the insulation.
- Do not bend or kink high voltage cables as this may damage the insulation.
- The round high voltage connectors are color coded with an exterior colored ring and mechanically coded with guide or code tabs. Observe the coding when connecting the round high voltage connector in order to avoid mechanical damage to the high voltage connector.
-- Remove the bolts -arrows- and the connection box cover -1-.
The connector -2- is ready to be removed.
-- Remove the bolts -2-.
The bolts -2- secure the Drive Motor High Voltage Wiring Harness -PX2- to the Electro-Drive Drive Motor -V141-.
-- Remove the wire holder -1- bolts -arrows-.
Risk of damaging the high voltage cables.
- Only remove the high voltage cables upward.
- Never turn or tip. There is a risk that the coding for the high voltage cable will become damaged.
-- Remove the high voltage cables -1- from each other and upward out of the connection box and tie them up.
-- Remove the bolts -1 and 2- and the bracket for the catalytic converter.
-- Remove the catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, NON-HYBRID VEHICLES or CATALYTIC CONVERTER, REMOVING AND INSTALLING, HYBRID VEHICLES .
-- Disconnect the coolant hoses for the hybrid engine radiators -1 and 2- using the Hose Clamps - Up To 25mm 3094.
-- Mark the coolant hoses -1 and 2- for reinstallation.
Risk of burning due to hot steam and hot coolant.
- The coolant system is under pressure when the engine is warm.
- Reduce pressure by cover coolant expansion tank cap with cloths and carefully opening.
-- Loosen the hose clamp at the connections with spring type clip pliers and disconnect the coolant hoses.
-- Seal the coolant connections and connections with plugs taken from the Engine Bung Set VAS6122.
-- Finally, remove the bolts -arrows- for the cold water control mount.
-- Loosen the engine wiring harness mount bolts -B- on the upper left -arrows- and the cold water control mount -A- bolts and tie up the mount and coolant hoses.
-- Then remove the ATF pipe bolts -1 and 2- on the transmission.
-- Remove the ATF pipe bolts on the engine -arrow 1- and transmission -arrow 2-.
Place the Used Oil Collection and Extraction Unit SMN372500 or Drip Tray under the transmission to catch any leaking ATF.
-- Remove the ATF pipes from the transmission and tie them up.
-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
- Do not touch contacts in transmission connector with hands.
-- To discharge static electricity, touch the transmission housing (without wearing gloves).
-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector from the transmission.
-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.
-- Remove the bolts -3- and remove the selector lever cable and cable bracket from the transmission and, if necessary, bind them upward.
Do not bend or kink the selector lever cable.
-- Remove the engine/transmission connecting bolts -2 through 5- on the transmission side.
The bolts -3 and 5- also attach the wire bracket on the transmission.
The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.
Remove the sleeve when removing the bolt at the top of the starter.
-- Place the Engine Support Bridge 10-222A with the Engine Support Bridge - Engine Bracket10-222A /1 and the Engine Support Bridge - Engine Support 310-222A/3, as shown in the illustration.
-- Engage the Engine Support Bridge - Spindle10-222A/11 on the front and rear engine lifting eyes.
-- Remove the torque support (bolts -1-) and torque crossbrace -3- (bolts -2-), refer to TORQUE SUPPORT AND CROSSMEMBER, REMOVING AND INSTALLING .
-- Remove the lower cover -1- from the transmission -arrow-.
-- Counterhold the crankshaft when loosening the bolts for the Electro-Drive Drive Motor -V141- with the Counterhold - Vibration Damper T10355.
Turn the crankshaft only in the direction of engine rotation.
Ignore -arrow-.
-- Continue turning the crankshaft 120° in the direction of engine rotation to remove the three Electro-Drive Drive Motor -V141- bolts -arrow- on the drive plate.
-- Remove the bolt -1- from the bottom of the starter on the engine side.
-- Remove the starter -A-. Pay attention to the locking piece -B- inside the opening in the starter, refer to STARTER, REMOVING AND INSTALLING, VEHICLES WITH 2.0L GAS/HYBRID .
The starter must be installed in order to install the locking piece -B- correctly in the starter opening when installing the transmission.
-- Remove the engine/transmission connecting bolt -arrow 2-.
-- Remove the engine/transmission connecting bolts -7 through 10-.
Do not remove the bolts -6- yet.
Danger of leaks in the ATF pan.
- The Gearbox Support T40173 must not be set on the ATF pan.
-- Place the Engine and Gearbox Jack VAS6031 with the prepared Gearbox Support T40173 on the bottom of the transmission (refer to "Preparing the Gearbox Support T40173: " (See Fig 2)).
-- The transmission support must be placed at the front as follows:
- Mount the bracket -2- on the left transmission side behind the opening for the Electro-Drive Drive Motor -V141- on the transmission.
- Mount the bracket -1- on the front final drive on the right side of the transmission.
-- Secure the transmission with a tensioning strap -1-.
The Gearbox Support T40173 is not illustrated.
-- Remove the bolts from the tunnel crossmember -arrows-.
-- Remove the last engine/transmission bolt.
-- Carefully separate the transmission from the engine slightly toward the rear.
-- Pay attention to the left transmission side steering pinion/steering gear.
-- Use spindles on the Gearbox Support T40173 to adjust the position of the transmission while lowering it.
Make sure the lines on the top of the transmission do not get pinched when lowering the transmission.
For further repairs on the transmission: Secure the transmission to the Engine And Transmission Holder VAS6095, refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .
Electro-Drive Drive Motor -V141-, Removing and Installing