Removing and installing gearbox, 6-cylinder petrol engine — AUDI

📋 Procedure

1. Remove engine compartment cover.
2. Remove lock carrier covers above headlights.
3. With ignition switched off, disconnect battery earth strap Electrical system27Disconnecting and connecting battery.
4. Remove plenum chamber cover General body repairs, exterior64Bonded windows; Removing and installing plenum chamber cover.
5. Remove left and right plenum chamber bulkhead panels from plenum chamber General body repairs, interior50Assembly overview – plenum chamber bulkhead.

6. Remove coolant expansion tank (1)19Cooling system/coolant.
7. Pull connector off bracket for vacuum reservoir (3).
8. Remove bracket for vacuum reservoir (3) from plenum chamber.
9. Remove noise insulation (4) from plenum chamber at front.
10. Detach fuel hoses (1) from retainer on battery housing and from bracket (2).
11. Unlock and pull off ABS control unit connector (3).
12. Swivel coolant hose (1) upwards (arrow), and lay it down on connector of ABS control unit (2).
13. Unscrew bolts (2) from support bracket for selector lever cable.
14. Remove selector lever cable (1) from lever/selector shaft by hand.
15. Do not kink or bend selector lever cable.
16. Remove intake hose (1).
17. Pull connector (2) out of holder and put it to one side.
18. Remove protective caps for suspension struts.
19. Fit adapters10-222A/23 onto suspension struts (arrow A) at rear and onto lock carrier (arrow B) at front.
20. Secure support bracket10-222A in conjunction with adapter10-222A/3 and adapter10-222A/16 left and right onto adapters10-222A/23.
21. Attach hook10-222A/2 in rear support eye of engine.
22. Slightly preload engine/gearbox assembly using spindle10-222A/11 and adapter10-222A/16.
23. Remove front left and front right wheel bolts.
24. Raise vehicle.
25. Remove front wheels.
26. Remove noise insulation below engine/gearbox.
27. Remove noise insulation for left and right drive shafts from wheel housing.
28. Remove exhaust system from subframe.
29. Remove subframe, noting that subframe needs to be secured Running gear, axles, steering40Removing and installing subframe.
30. Press left drive shaft off gearbox stub shaft, and secure it to body Running gear, axles, steering40Removing and installing drive shafts.
31. Remove right drive shaft (A) from torque reaction support (arrows) of engine. Pull drive shaft off gearbox stub shaft, and secure it to body.
32. Position drip tray for workshop hoistVAS 6208 under vehicle.
33. Unscrew nut (arrow) of ATF lines and pull ATF lines out of gearbox.
34. Seal gearbox connections and ATF lines with clean plugs.
35. Unlock and pull off connectors (1) and (2) of both gearbox wiring harnesses.
36. Remove starter motor Electrical system27Starter; Removing and installing starter.
37. Position engine and gearbox jackV.A.G 1383/A with universal supportV.A.G 1359/2 under final drive and exert slight counter pressure.
38. Remove hexagon bolts (arrows A) of left assembly mounting.
39. Remove engine and gearbox jackV.A.G 1383/A with universal supportV.A.G 1359/2 from under final drive.
40. Now step onto step ladderVAS 5085 to lower engine/gearbox assembly using adapter and spindle.
41. Using adapter10-222A/16 and spindle of support bracket10-222A, lower engine/gearbox assembly to dimension (a). [Note: Measure dimension (a) between lower side of longitudinal member (1) and bolting surface of assembly mounting (2).]
42. Then unscrew assembly mounting (arrows B) from gearbox. [Note: Assembly mounting of gearbox is secured with three bolts. The third bolt is not visible in the figure.]
43. Unhook both hydraulic lines for power steering from retainer (A) next to left longitudinal member.
44. Unbolt torque converter from drive plate (arrow).
45. Remove engine/gearbox connecting bolt in area of support bracket for selector lever cable in starter mounting.
46. Remove front lower engine/gearbox connecting bolts.
47. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383/A.
48. Align arms of gearbox support according to holes in adjustment plate.
49. Position engine and gearbox jackV.A.G 1383/A with gearbox support3282 under vehicle.
50. Take nut (2) that was used for securing ATF lines and screw it back on the "“other way round”". The flange of the nut faces away from the gearbox.
51. Secure arm of gearbox support3282 onto gearbox with another nut (1).
52. Insert pin of gearbox support3282 into final drive support (arrow).
53. Remove rear engine/gearbox connecting bolts (arrows).
54. Press gearbox off engine (dowel sleeves). At the same time, push torque converter in direction of (arrow) out of drive plate.
55. Secure torque converter against falling out .
56. Slowly lower gearbox with engine and gearbox jackV.A.G 1383/A. [Note: Clean ATF cooler and ATF lines before installing an exchange gearbox .Before installing gearbox, ensure that torque converter seats correctly in gearbox .Before installation, check dowel sleeves are correctly installed and seated properly.Missing dowel sleeves result in misalignment of the axes of engine and gearbox, leading to destruction of the sleeve bearing and torque converter hub.]
57. Turn torque converter and drive plate so that one threaded pin in torque converter and one hole in drive plate are centred in access hole of gearbox housing.
58. Renew retaining ring on left stub shaft if same gearbox is being reinstalled.
59. At same time, press old retaining ring out of stub shaft with new retaining ring (arrow).
60. Lubricate left and right stub shaft splines with all-purpose greaseG 052 735.

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