Transmission, Removing: Overview

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2013 Audi S5, 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, and 2009 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Remove Audi A5, 4.2L FSI transmission

Through VIN 8T-8A-023117, the Audi A5, 4.2L FSI engine's transmission can only be removed together with the engine. Refer to the appropriate service information

Special Tools And Workshop Equipment Required

Counterhold Tool Touareg V10 T10172 with Adapter T10172/5
Release Tool f/ Rev. Light Switch Conn. T40138
Puller for Gear Shaft Linkage T40160
Transmission Support T40173
Jointed Socket, 12 mm T40220
Engine/Transmission Jack V.A.G 1383 A
Extractor T40176

Removing

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- Position the front wheels so they are straight.

-- Turn off the ignition and remove the key.

-- Disconnect the ground (GND) cable -2- from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 1: Identifying Battery

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-- Remove the engine cover -arrows-.

Fig 2: Removing Engine Cover

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-- Just loosen the wheel bolts on the front wheels; do not remove the wheels.

-- Lift the vehicle.

-- Remove the noise insulation by loosening the fasteners -1 through 3-.

Fig 3: Identifying Noise Insulation Components

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-- Remove the bolt -1- for the power steering hydraulic fluid line.

CAUTION:

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.

Fig 4: Identifying Subframe Crossbrace

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-- Remove the nuts -arrows- for the left front muffler.

Fig 5: Identifying Left Front Muffler Nuts

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-- Remove the nuts -arrows- for the right front muffler.

Fig 6: Identifying Right Front Muffler Nuts

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CAUTION:

Danger of damaging the flex joint in the front muffler.

Do not bend the decoupling element in the front muffler more than 10°.

-- Loosen the clamping sleeves -1- and -2-, push toward the rear, and remove the left and right front muffler.

Fig 7: Identifying Bolts Vehicles With Dual Exhaust System

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-- Disconnect the connectors -1- from the steering gear and -2- from the engine speed sensor -G28-.

Fig 8: Disconnecting Connectors And Free Up Electric Wires

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-- Remove the lower cover -1- from the transmission -arrow-.

Fig 9: Identifying Transmission Lower Cover

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Put in sixth gear; to do this, move the gearshift shaft -1-, push the gearshift lever -2- forward in direction of -arrow-.

Fig 10: Identifying Gearshift Assembly
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Use the T10172 and T10172/5 to block the driveshaft to keep it from turning, too.

Fig 11: Holding Driveshaft Using T10172

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-- Remove the 6 bolts -arrow- from the drive plate. Do this by continuing to rotate the clutch module over both front wheels 60° each.

Fig 12: Identifying Clutch Module First Bolt Installation Location

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-- Remove the front wheels.

-- Remove the left and right noise insulation -1- inside the wheel housing.

Fig 13: Identifying Noise Insulation -1-

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-- Remove right and left subframe shield -1- (if equipped). Do this by removing the bolts -arrows- and then removing the shield toward the inside.

Fig 14: Removing Subframe Heat Shield

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-- Remove the nuts -arrows- and the bolt -1- and push the catalytic converter to the right side.

Fig 15: Removing Nuts And Bolt Pushing Catalytic Converter To Right Side

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NOTE:

The illustration shows the installation position with the engine removed.

Use the T40220 to loosen the nuts -arrow-, right catalytic converter -A- on the exhaust manifold.

Fig 16: Using T40220 To Loosen Nuts

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Secure the right catalytic converter loosely using a nut so it does not fall down.

-- Remove the rear coolant pipe. Refer to COOLANT PIPES .

-- Remove the air duct -arrow-.

Fig 17: Removing Air Duct

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-- Disconnect the connector -1- on the Mass Airflow (MAF) Sensor -G70-.

Fig 18: Disconnecting Connector On Mass Airflow (MAF) Sensor

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-- Remove the vacuum hose -3- to the air duct pipe.

CAUTION:

There is a risk of violating emissions regulations.

Do not open the hose connection -2- !

-- Lay aside the air guide hose with the crankcase ventilation hose connected -2- by loosening the hose clamps -4- and opening the clips -arrows-.

-- Disconnect the vacuum line -1-.

Fig 19: Intake Air Switch-Over Valve -N335- -2-

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-- Remove the air filter housing lower section and disconnect the electrical connector -2- on the intake air switch-over valve -N335- on the back.

-- Disconnect the hose -3- to the secondary air injection pump.

-- Remove the coolant hose from the radiator -2- and from the right coolant pipe -1-.

Fig 20: Removing Coolant Hose From Radiator And Right Coolant Pipe

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-- Remove the bolts -1- and -2- and the coolant hose -arrow-.

Fig 21: Removing Bolts And Coolant Hose

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-- Remove the right coolant pipe from the connection and lay it aside.

-- Remove the bolts -1- and -2- and the coolant connection.

Fig 22: Removing Bolts And Coolant Connection

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NOTE:

Ignore -arrow-.

-- Remove the connecting rod bolt -3- from the top.

Fig 23: Identifying Bolts For Selector Rod And Push Rod

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NOTE:

Ignore -1 through 2-.

-- Remove the bolts -2 through 6- connecting the engine to transmission. They are accessible from above.

Fig 24: Removing Starter Off Transmission And Leave It In Installation Position

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-- Remove the bolts -arrows-, and remove the driveshaft heat shield -A- (if equipped).

Fig 25: Identifying Driveshaft Heat Shield

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Driveshaft Bolted on the Transmission Side:

-- Remove the bolts that connect the driveshaft to the transmission by counterholding them with the T10172 and T10172/5.

Fig 26: Holding Driveshaft Using T10172

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-- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

-- Secure the driveshaft to the side.

Driveshaft Mounted on the Transmission Side:

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE or DRIVESHAFT ATTACHED ON TRANSMISSION SIDE .

All Vehicles:

-- Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Fig 27: Removing Bolt And Secure Clutch Slave Cylinder Sideways In Engine Compartment

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CAUTION:

The clutch slave cylinder could be damaged.

Do not press the clutch pedal after the clutch slave cylinder has been removed.

-- Remove the nut -1-.

CAUTION:

Danger of causing damage to the gearshift shaft inside the transmission.

Do not pry off the transmission shift lever -1- using a pry bar or hit it with a hammer.

Fig 28: Positioning Puller T40160 And Remove Selector Rod

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-- Install the T40160 and remove the transmission shift lever -1-.

CAUTION:

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 universal joint bolt -arrow-. Refer to STEERING COLUMN, HANDLING AND TRANSPORTING .

Fig 29: Locating Universal Joint Bolt

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-- Press the universal joint off the steering gear and slide it all the way up.

-- Remove the bolt -1- press the retaining tab off the transmission and tilt it back -arrow-.

Fig 30: Removing Bolt Press Retaining Tab Off Transmission And Tilt It Back

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-- Remove the bolt -1- from the starter.

Fig 31: Removing Starter Off Transmission And Leave It In Installation Position

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-- Remove the starter from the transmission and leave it in the installation position.

-- Remove the remaining bolts -7 through 11- that attach the engine to the transmission.

-- Position the V.A.G 1383 A and the T40173 under the transmission and secure it with the tensioning strap -1- as illustrated.

Fig 32: Identifying Transmission Holding Fixture

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-- Remove the bolts from the tunnel crossmember -arrows-.

Fig 33: Identifying Bolts & Tunnel Crossmember

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-- Lower the transmission using the V.A.G 1383 A first to dimension -a-.

Fig 34: Lowering Transmission

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Dimension -a- = maximum 100 mm.

-- Remove the bolts -arrows- and remove the heat shield from the right drive axle.

Fig 35: Driveshaft Heat Shield - Tightening Specification

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove the bolts -arrows- and the left drive axle heat shield.

Fig 36: Removing Bolts And Left Drive Axle Heat Shield

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove the left and right drive axles from the transmission flange shafts -arrows-.

Fig 37: Removing Left And Right Drive Axles

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-- Remove the electrical connector -1- on the transmission range gear recognition switch -F208- using the T40138.

Fig 38: Disconnecting Connector

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-- Remove the push rod bolt -2-.

NOTE:

Ignore -3-.

-- Press the transmission off the engine and lower it carefully using the V.A.G 1383 A.

If the transmission removed is being replaced, then the following components must be changed:

Right and left bracket -1- for the exhaust system. Refer to EXHAUST SYSTEM, EMISSION CONTROLS .

Fig 39: Identifying Exhaust System Retaining Strap Bracket
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Tunnel crossmember with the transmission mount and transmission support. Refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .
Remove the clutch module if necessary. Refer to CLUTCH MODULE .

Fig 40: Sliding Torque Converter Carefully Onto Input Shaft
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