Removing gearbox on vehicles with 6-cylinder petrol engine — AUDI

🧭 Before you start

Disconnect the battery, remove the rear engine cover, move the expansion tank and unplug the post-catalyst lambda probes. Separate the front exhaust pipes, take out the noise insulation, cross members and exhaust brackets, then unbolt drive shafts, selector rods and slave cylinder. Slide the propshaft rearwards and tie it up, reset the torque reaction support stop, and remove the accessible bell housing bolts. Mount the gearbox on the prepared support, remove the tunnel cross member and last two bolts, then lower it off the dowels.

Fits: Audi A6 C6 (4F, 2004–2011)

Don't miss

• Do not press the clutch pedal with the slave cylinder removed; it is destroyed above approx. 300 N.
• The flexible exhaust connection must not bend more than 10°.
• Keep the lock carrier fitted, not in service position, while adjusting the torque reaction stop.
• Drill the 10.2 mm hole in the support elements before mounting the gearbox support.
• Tighten the gearbox support element bolts to 20 Nm.
• Transfer the gearbox support (2) to a replacement gearbox.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ Follow steps required when disconnecting battery 27. — Switch off ignition and remove ignition key.
2. Take out luggage compartment floor covering.
3. Disconnect earth wire (arrow) at battery.
4. Pull off rear engine cover panel (arrows).
5. Unbolt coolant expansion tank (arrow).

6. Unplug electrical connector for coolant shortage indicator switch F66 at expansion tank (bottom) and move expansion tank clear to one side, with coolant hoses (1) and (2) attached.
7. Unplug electrical connector (2) for Lambda probe 2 after catalytic converter G131 and move electrical wire clear from below. [Note: (Item 1) can be disregarded.]
8. Unscrew nut (2) (access from above), connecting left front exhaust pipe with exhaust manifold. [Note: For illustration purposes here shown from rear, with engine removed.]
9. Pull non-return valve (1) off air intake hose.
10. Slacken hose clip (2) and release clamps (arrows) to remove air intake hose.
11. Unplug electrical connector (2) for Lambda probe after catalytic converter G130 and move electrical wire clear from below. [Note: (Item 1) can be disregarded.]
12. Unscrew nut (2) (access from above), connecting right front exhaust pipe with exhaust manifold. [Note: For illustration purposes here shown from rear, with engine removed.]
13. Remove bolts accessible from above (4) and (5).
14. Remove both front wheels. [Note: Secure brake discs with wheel bolts.]
15. Release fasteners marked (1), (2) and (arrow) (if fitted) and remove noise insulation panels.
16. Unbolt heat shields for drive shafts (left and right) from gearbox (arrows).
17. Unscrew cross member from subframe (arrows).
18. Remove front cross member (arrows).
19. Unscrew bolts (1) and (2) and remove front exhaust pipe bracket (left-side).
20. Unscrew nuts (1) and (3) (accessible from below) connecting front exhaust pipe to exhaust manifold.
21. Move Lambda probe wire clear (downwards).
22. Unscrew bolts (1) and (2) and remove front exhaust pipe bracket (right-side).
23. Unscrew nuts (1) and (3) (accessible from below) connecting front exhaust pipe to exhaust manifold.
24. Move Lambda probe wire clear (downwards). [Note: The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged.]
25. Unscrew bolts (1) and (2) at rear bracket for front exhaust pipes. [Note: (Item 3) can be disregarded.]
26. Unbolt drive shafts (left and right) from gearbox flange shafts.
27. Unplug electrical connector (arrow) for reversing light switch F4 and move electrical wire clear.
28. Unscrew connecting rod (2) for selector rod.
29. Unscrew push rod (1), using an 8 mm hexagon key when unscrewing bolt.
30. Unscrew nut (arrow) and detach gearbox selector lever from selector shaft.
31. Remove clutch slave cylinder (arrow) and tie up with wire. Do not disconnect hoses/pipes.
32. ⚠ Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. — Unplug connector (arrow) for engine speed sender G28 on left side of gearbox.
33. Unscrew heat shield for propshaft (A)(arrows).
34. Unscrew bolts at gearbox/propshaft flange.
35. Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.
36. Tie the propshaft to side, onto body (arrow).
37. ⚠ Make sure that the lock carrier remains installed during the following work steps and is not in the service position. — Slacken bolts (arrows) at stop for torque reaction support.
38. Press stop for torque reaction support upwards and tighten bolts again. [Note: Adjusting the stop for torque reaction support prevents the engine from tilting at the front after the gearbox is removed.]
39. Remove bolts (1), (2) and (7 … 10). [Note: Bolts (3) and (6) remain screwed in hand-tight.]
40. Drill a hole of 10.2 mm ∅ (arrow) in the support elements of gearbox support3282.
41. To remove manual gearbox 02X set up gearbox support3282 with adjustment plate3282/43 and place on engine and gearbox jackV.A.G 1383 A. [Note: The support elements(arrows A) and (arrows B) are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points in the direction of travel.Adjustment plate can only be fitted in one correct position.]
42. Align the adjustment plate parallel to the gearbox.
43. Secure the support elements to the left side of the gearbox, as shown in illustration. Tighten bolt (arrow on right side) to 20 Nm. — 20 Nm (15 lb-ft)
44. Secure the support elements to the right side of the gearbox, as shown in illustration. Tighten bolt (arrow on left side) to 20 Nm. — 20 Nm (15 lb-ft)
45. Remove bolts (arrows) and detach tunnel cross member.
46. Remove the last two engine/gearbox securing bolts.
47. Unseat gearbox from dowel sleeves and lower carefully with engine and gearbox jackV.A.G 1383 A. [Note: When lowering gearbox, make sure that all wires are disconnected on the top of the gearbox.When lowering gearbox, make sure there is sufficient clearance for drive shafts.]
48. If the removed gearbox is being renewed, the gearbox support (2) must be transferred to the replacement gearbox.

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