Removing gearbox - vehicles with 2.0 ltr. TDI engine (PR TD1) — AUDI

🧭 Before you start

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

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• Bolt (2) also secures the bracket for wiring.Bolt (2) secures the starter to the gearbox and has an additional spacer sleeve (arrow).
• Place a cloth below the connection to catch escaping ATF.
• Risk of damage to parts of the running gear.Do not let the vehicle down on the wheels if the gearbox mounting, steering rack or subframe cross brace are not properly installed. — Pull cover (1) off bottom of gearbox (arrow).
• When you then turn the crankshaft, turn only in direction of engine rotation (arrow).
• The exhaust pipe remains installed.

📋 Procedure

1. Bring front wheels into straight-ahead position.
2. ⚠ When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — Disconnect earth wire (2) from battery terminal Electrical system27Battery; Disconnecting and connecting battery.
3. ⚠ Risk of damage to the engine cover panel.Pull out engine cover panel evenly, without jerking. — Carefully detach engine cover panel from retaining studs one by one in direction of (arrows). Pull out engine cover panel evenly, without jerking.
4. Remove plenum chamber partition panel General body repairs, exterior50Bulkhead; Exploded view - plenum chamber partition panel.
5. Unplug electrical connectors (1, 2).

6. ⚠ Risk of irreparable damage to exhaust gas pressure sensor 1G450 and pressure differential sender G505.Connections of exhaust gas pressure sensor 1G450 and pressure differential sender G505 can break off if too much pressure is applied. — Remove bolt (3) and carefully push bracket with exhaust gas pressure sensor 1G450 and pressure differential sender G505 to the side.
7. Remove bolts (2 … 5) securing gearbox to engine (accessible from above). [Note: Bolt (2) also secures the bracket for wiring.Bolt (2) secures the starter to the gearbox and has an additional spacer sleeve (arrow).]
8. Remove noise insulation (1) and (2)General body repairs, exterior66Noise insulation; Removing and installing noise insulation.
9. Remove cover (1) for drive shaft from wheel housing (both sides).
10. Remove bolt (arrow) for ATF line.
11. Remove subframe cross brace Running gear, axles, steering40Subframe; Removing and installing subframe cross brace. [Note: Place a cloth below the connection to catch escaping ATF.]
12. Unscrew bolts (arrows), detach ATF lines (1) from gearbox and tie up to one side.
13. Seal off open lines and connections with clean plugs from engine bung setVAS 6122.
14. Detach intermediate steering shaft from steering rack and telescope shaft upwards Running gear, axles, steering48Steering column; Exploded view - steering column.
15. ⚠ Risk of damage to parts of the running gear.Do not let the vehicle down on the wheels if the gearbox mounting, steering rack or subframe cross brace are not properly installed. — Pull cover (1) off bottom of gearbox (arrow).
16. Remove trim cap from vibration damper.
17. To slacken bolts for flywheel, counterhold crankshaft with angled ring spanner (1) at vibration damper. [Note: When you then turn the crankshaft, turn only in direction of engine rotation (arrow).]
18. Remove 3 bolts (arrow) for flywheel (turn crankshaft 120° in direction of engine rotation each time).
19. Remove bolt (2) for retainer.
20. Push retainer (1) in direction of (arrow B) and pivot to the rear (arrow A). [Note: The exhaust pipe remains installed.]
21. Remove bolts (arrows) and detach heat shield for drive shaft (right-side). [Note: The installation position is shown with the gearbox removed.]
22. Unbolt drive shafts (left and right) from flange shafts on gearbox.
23. Use removal lever80 - 200 to press ball socket (1) on selector lever cable off gearbox selector lever.
24. Remove bolts (2) for cable support bracket.
25. Move selector lever cable clear. [Note: Do not bend or kink the selector lever cable.]
26. ⚠ The gearbox control unit (mechatronic unit) can be irreparably damaged by electrostatic discharge.Before handling electrical connectors, mechanic must discharge static. To do so, touch vehicle earth, heater radiator, or lifting platform, with your hand.Do not touch contact pins in gearbox connector with bare hands. — Unplug electrical connector (arrow) at gearbox.
27. Unplug electrical connector (2) from power steering control unit J500 (to do so, release retainer (arrow) and press down release catch).
28. Move electrical wiring harness clear. [Note: (Item 1) can be disregarded.]
29. Remove bolt (1) for starter.
30. Detach starter from gearbox but do not remove starter.
31. Remove remaining engine/gearbox securing bolts (6 … 10).
32. 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.
33. Remove tunnel cross member Removing and installing tunnel cross member.
34. Loosen bolt (1) for torque reaction support (2).
35. Lower gearbox using engine and gearbox jackV.A.G 1383 A just enough so that torque reaction support is positioned at very bottom of its adjustment range (arrow).
36. Tighten bolts and insert piston compressing tool T40142 as a spacer, as shown in illustration.
37. Detach gearbox from engine and lower carefully using engine and gearbox jackV.A.G 1383 A.

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