Removing gearbox - Audi A4, A5 with 3.0 ltr. TDI engine — AUDI

🧭 Before you start

Fits: Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015), Audi A5 (8T, 2007–2016)

• Special tools named: T40160, puller

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• When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — Loosen fasteners (1 … 3) and remove noise insulation panels.
• (Items 1 and 2) can be disregarded.
• Risk of damage to clutch slave cylinder.Do not depress clutch pedal after removing slave cylinder. — Remove nut (1).
• Use stepladderVAS 5085 for access to spindle10 - 222 A /11 while vehicle is raised.
• Bolt (3) was removed at an earlier stage.

📋 Procedure

1. Bring front wheels into straight-ahead position.
2. Switch off ignition and take out ignition key.
3. Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
4. ⚠ When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — Loosen fasteners (1 … 3) and remove noise insulation panels.
5. Detach noise insulation (1) from wheel housing (both sides).

6. Remove subframe cross brace (1)Running gear, axles, steering40Subframe; Removing and installing subframe cross brace.
7. ⚠ Risk of damage to parts of the running gear.Do NOT let the vehicle down on the wheels if the subframe, steering rack or subframe cross brace are not properly installed. Do NOT support the vehicle at the subframe or the subframe cross brace (e.g. with a trolley jack). — Detach intermediate steering shaft from steering rack and telescope shaft upwards Running gear, axles, steering48Steering column; Exploded view - steering column.
8. ⚠ Risk of damage to coil connector for airbag.Front wheels must be in straight-ahead position when universal joint is detached from steering rack.Do not change position of steering wheel or steering rack after this step (if necessary, fix steering wheel in position with adhesive tape). — Remove engine cover panel (arrows).
9. Remove front exhaust pipe and particulate filter 26Exhaust pipes/silencers; Exploded view - silencers.
10. Working from plenum chamber cover, remove bolt (3) for connecting rod. [Note: (Items 1 and 2) can be disregarded.]
11. Remove bolts (2 … 5) securing gearbox to engine (accessible from above).
12. Set up support bracket10 - 222 A with rack10-222 A /1 and spindle10 - 222 A /11 as shown in illustration.
13. Engage 6th gear by pulling out selector shaft (1) and shifting gear selector lever (2) forwards in direction of (arrow).
14. Pull cover (1) off bottom of gearbox (arrow).
15. Remove 6 bolts (arrow) securing clutch module to drive plate (rotate clutch module/drive plate 60° further each time by turning both front wheels).
16. Remove bolt (2), pull clutch slave cylinder out of gearbox and tie up to side in engine compartment.
17. ⚠ Risk of damage to clutch slave cylinder.Do not depress clutch pedal after removing slave cylinder. — Remove nut (1).
18. Apply puller T40160 and pull off gearbox selector lever (1).
19. ⚠ Risk of damage to selector shaft in gearbox. Do not prise off or knock off the gearbox selector lever (1) with a lever or hammer.Always use puller T40160 when removing the gearbox selector lever. — Remove subframe shield (right-side) (1); to do so, unscrew bolts (arrows) and detach heat shields towards inside.
20. Remove bolts (arrows) and detach heat shield for drive shaft (right-side).
21. Unbolt drive shafts (left and right) from flange shafts on gearbox.
22. ⚠ Risk of scalding from hot steam and hot coolant.The cooling system is under pressure when the engine is hot.Cover filler cap on expansion tank with a cloth and open carefully to release pressure. — Clamp off both coolant hoses on gearbox using hose clamps up to 25 mm3094.
23. Place drip tray below gearbox, open spring-type clip (1) and disconnect both coolant hoses.
24. Position engine and gearbox jackV.A.G 1383 A with gearbox support T40173 underneath gearbox and secure with tensioning strap (1) as shown in illustration.
25. Remove bolts (arrows) for tunnel cross member.
26. Lower gearbox initially only by dimension (a) using engine and gearbox jackV.A.G 1383 A.
27. Partly take up weight of engine with spindle10 - 222 A /11. [Note: Use stepladderVAS 5085 for access to spindle10 - 222 A /11 while vehicle is raised.]
28. Remove bolt (2) for push rod.
29. Disconnect electrical connector (1) for gear detector switch F208 using release tool T40138 and move wiring clear. [Note: Bolt (3) was removed at an earlier stage.]
30. Unplug electrical connector from gearbox neutral position sender G701(arrow) and move wiring clear. [Note: Different connectors for gear detection sensor G604.]
31. Push catch (1) downwards, unplug connector (2) and move electrical wiring clear.
32. Use screwdriver to pry out catch (1) approx. 3 mm in direction of (arrow A).
33. Push catch (1) downwards in direction of (arrow B), unplug connector (2) and move electrical wiring clear.
34. Remove bolt (1) for starter from engine side.
35. Detach starter from gearbox but do not remove starter.
36. Remove remaining engine/gearbox securing bolts (6 … 11).
37. Detach gearbox from engine and lower carefully using engine and gearbox jackV.A.G 1383 A.
38. If the removed gearbox is being replaced, the following components must be transferred to the replacement gearbox:

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