Removing gearbox on vehicles with V8 4.2 ltr. FSI engine — AUDI

🧭 Before you start

Disconnect the battery earth, remove the plenum covers and body brace, and take the engine weight on the support bracket. Remove wheels, noise insulation, liners, ATF cooler, cross members, heat shields, drive shafts, right engine support and starter, then the torque converter bolts. Detach the front silencers, slide the propshaft back and tie it up, and free the gearbox mountings, selector cable, ATF pipes and connector. Set up the gearbox support on the jack, lower the assembly evenly, remove the bell housing bolts, pull the gearbox off the dowels and secure the torque converter.

Fits: Audi A8 D3 (4E, 2002–2010)

• Special tools named: T40093/6, T40058
• Renewed: gearbox oil pan

Don't miss

• Discharge static by touching the gearbox housing before handling the mechatronic connector.
• The flattened side of bolt 3282/50 must face the oil pan, or the pan can be bent.
• Do not bend the flexible joint in the front exhaust pipe further than 10°.
• Secure the torque converter with support bridge 30-211 A as soon as the gearbox is clear.
• Refit every released or cut cable tie in its original position.

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

📋 Procedure

1. Observe all the repair instructions . [Note: All cable ties which are released or cut open during removal must be fitted in the same position when installing.]
2. ⚠ Follow steps required when disconnecting battery Electrical system27. — Switch off ignition.
3. Remove cover in luggage compartment side trim (right-side) (arrows).
4. Remove battery cover (1). [Note: (Item 2) can be disregarded.]
5. Disconnect earth wire (arrow) at battery.

6. Pull off rear engine cover panel (arrows).
7. Pull rubber seal (1) off plenum chamber covers.
8. Detach plenum chamber covers (2) and (3).
9. Remove rear securing bolts (3) for body brace.
10. Attach adapters10 - 222 A /21 to suspension turrets without the adapter10 - 222 A /4.
11. Fit adapter10 - 222 A /4 with adapters T40093/6 and adapters 10 - 222 A /21.
12. Secure spindles 10 - 222 A /11 to engine lifting eyes.
13. Take up some of the engine weight by tightening spindles of support bracket, but do not lift.
14. Remove both front wheels.
15. Remove noise insulation panels (loosen fasteners (1, 2, 4)). [Note: (Item 3) can be disregarded.]
16. Remove front section of front wheel housing liner (left and right) General body repairs, exterior66.
17. Move air hose for secondary air system (1) clear from bracket for ATF cooler
18. Remove bolts (arrows) and detach ATF cooler.
19. Tie ATF cooler onto engine (coolant hoses remain connected to ATF cooler).
20. Unscrew bolts (1) and remove bracket for noise insulation.
21. Unscrew bolts (2) and remove cross member.
22. Remove heat shield for drive shaft (left-side) (arrows). [Note: For illustration purposes here shown with engine removed.]
23. Remove heat shield for drive shaft (right-side) (arrows).
24. Remove drive shafts (left and right) from gearbox flange shafts.
25. Remove bolts (1 and 2) (on left and right) for anti-roll bar mountings.
26. Remove bolts (3 and 4). [Note: (Items 1 and 2) can be disregarded.]
27. Remove bolts (arrows) for engine mountings (left and right).
28. Detach engine cross member.
29. Unplug electrical connector (2) at engine mounting (right-side).
30. Remove bracket for electrical wiring from engine support (right-side) (1).
31. Remove bolts (arrows) and remove engine support (right-side) together with engine mounting. [Note: Detach B+ wire only after unplugging electrical connector for terminal 50.]
32. Unscrew earth wire (1).
33. Disconnect wires (3) and (4).
34. Unscrew bolts (2) and (5) and remove starter.
35. Insert guide pin of adapter T40058 so that the small diameter (arrow 2) faces engine. The larger diameter (arrow 1) faces adapter.
36. Counter-hold crankshaft using adapter T40058 to slacken torque converter bolts. [Note: (Arrow) can be disregarded.]
37. Unscrew the 3 Torx socket head bolts (arrows) of the torque converter through the opening for the removed starter (turning the crankshaft 1/3 turn each time).
38. Unbolt front cross piece (arrows).
39. Unscrew nuts (1) for front silencer (left-side).
40. Remove bolt (3). [Note: (Item 2) can be disregarded.]
41. Unscrew nuts (1) for front silencer (right-side).
42. Remove bolt (2) and detach spring element.
43. ⚠ The flexible joint in the front exhaust pipe can be damaged. The flexible joint in the front exhaust pipe must not be bent further than 10°. — Unscrew nuts (arrows) from retaining lugs for front silencers.
44. Disconnect exhaust system at clamps (1 and 2) and detach front silencers.
45. If fitted, unbolt heat shield (A) for propshaft (arrows).
46. Remove bolts at connection between propshaft and gearbox.
47. Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.
48. Tie up propshaft to body.
49. Unscrew bolts (arrows) for front gearbox mountings (left and right).
50. Remove bolts (arrows) and detach gearbox support (left-side) with gearbox mounting. [Note: (Item 1) can be disregarded.]
51. Remove bolts (arrows) and detach gearbox support (right-side) with gearbox mounting.
52. Use removal lever80 - 200 to pry ball socket (1) on selector lever cable off selector shaft lever.
53. Unclip locking plate (2) from support bracket for selector lever cable.
54. Remove bolt (3) and move selector lever cable clear to one side.
55. Remove nut (arrow) and detach ATF pipes from bracket.
56. Remove bolt (arrow) at bracket for ATF pipes.
57. Remove bolt (arrow) and detach ATF pipes from gearbox.
58. Remove bolt (1) at bracket for coolant pipe bottom left). [Note: (Items 2 ... 4) can be disregarded.]
59. ⚠ The gearbox control unit (mechatronic unit) can be damaged by electrostatic discharge.Do not touch contact pins in gearbox connector with bare hands. — Touch gearbox housing with your hand (without gloves) to discharge any static electricity.
60. Disconnect electrical connector at gearbox by turning fastener cap anti-clockwise (arrow).

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