Removing gearbox - vehicles with 3.0 ltr. TFSI engine: Audi A5 / A4 B8

🧭 Before you start

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

• Special tools named: T10172/5

Don't miss

• When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — Bring front wheels into straight-ahead position.
• The installation position is shown for a vehicle with dynamic steering.
• Risk of damage to flexible joint in front silencer.The flexible joint in the front silencer must not be bent further than 10°. — Unbolt clamps (1) and (2), push clamps towards rear and detach front silencers (left and right).
• Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool T10172 and T10172/5).
• (Item 1) can be disregarded.

📋 Procedure

1. ⚠ When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — Bring front wheels into straight-ahead position.
2. Switch off ignition and take out ignition key.
3. Disconnect earth wire (2) from battery terminal Electrical system27Battery; Disconnecting and connecting battery.
4. Lift off engine cover panels (1) and (2)(arrows).
5. Set up support bracket10 - 222 A with adapter T40093/6 on suspension turrets (left and right), as shown in illustration.

6. Hook spindles10 - 222 A /11 onto engine lifting eyes (left and right).
7. Partly take up weight of engine via the spindles.
8. Remove both front wheels.
9. Detach noise insulation (1) from wheel housing (both sides).
10. Loosen fasteners (1 … 3) and remove noise insulation panels.
11. ⚠ 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). — Remove nut (1) for hydraulic line for power steering.
12. Remove bolts (arrows) and detach subframe cross brace. [Note: The installation position is shown for a vehicle with dynamic steering.]
13. To remove subframe shield (1) (left and right), unscrew bolts (arrows) and take out shield towards inside.
14. Remove nuts (arrows) securing front silencer (left-side).
15. Remove nuts (arrows) securing front silencer (right-side).
16. ⚠ Risk of damage to flexible joint in front silencer.The flexible joint in the front silencer must not be bent further than 10°. — Unbolt clamps (1) and (2), push clamps towards rear and detach front silencers (left and right).
17. If fitted, remove bolts (arrows) and detach heat shield (A) for propshaft.
18. Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool T10172 and T10172/5).
19. Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.
20. Tie propshaft up to one side.
21. Remove propshaft Rear final drive39Propshaft; Removing and installing propshaft.
22. Unplug electrical connector (2) at engine speed sender G28 and move wiring clear. [Note: (Item 1) can be disregarded.]
23. Pull cover (1) off bottom of gearbox (arrow).
24. Insert guide stud of adapter T40058 as follows:
25. To slacken bolts securing clutch module to drive plate, counterhold crankshaft with adapter T40058 and angled ring spanner. [Note: When you then turn the crankshaft, only turn crankshaft in direction of engine rotation (arrow).]
26. Remove 6 bolts (arrow) securing clutch module to drive plate (turn clutch module by turning crankshaft 60° in direction of engine rotation each time).
27. Remove engine/gearbox securing bolts (7 … 11).
28. ⚠ 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 bolt (arrow) for universal joint Running gear, axles, steering48Steering column; Exploded view - steering column.
29. Press universal joint off steering rack and push all the way up.
30. Place used oil collection and extraction unitV.A.G 1782 below hydraulic line connection (1) at steering rack.
31. Remove bolts (arrows), detach hydraulic line (1) from steering rack and place to one side. [Note: Seal off open lines and connections with clean plugs from engine bung setVAS 6122 to prevent dirt from entering.]
32. Remove bolt (1), press retainer off gearbox and swivel back towards rear (arrow).
33. Remove bolt (2) and tie up clutch slave cylinder to side in engine compartment.
34. ⚠ Risk of damage to clutch slave cylinder.Do not depress clutch pedal after removing clutch slave cylinder. — Remove nut (1) for selector rod.
35. ⚠ 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. — Apply puller T40160 and pull off gearbox selector lever (1).
36. 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.
37. Remove bolts (arrows) on tunnel cross member.
38. Lower gearbox initially only by dimension (a) using engine and gearbox jackV.A.G 1383 A.
39. Pre-tension spindles10 - 222 A /11 on support bracket10 - 222 A slightly. [Note: Use stepladderVAS 5085 for access to spindles10 - 222 A /11 while vehicle is raised.]
40. Remove bolt (2) for push rod.
41. Remove bolt (3) for connecting rod.
42. Disconnect electrical connector (1) for gear detector switch F208 using release tool T40138 and move wiring clear.
43. Push catch (1) downwards, unplug connector (2) and move electrical wiring clear.
44. Use screwdriver to pry out catch (1) approx. 3 mm in direction of (arrow A).
45. Push catch (1) downwards in direction of (arrow B), unplug connector (2) and move electrical wiring clear.
46. Remove bolts (arrows) and detach heat shield for drive shaft (right-side). [Note: The installation position is shown with the gearbox removed.]
47. Remove bolts (arrows) and detach heat shield for drive shaft (left-side). [Note: The installation position is shown with the gearbox removed.]
48. Unbolt drive shafts (left and right) from flange shafts on gearbox (arrows).
49. Remove nuts (arrows) and bolt (1), press catalytic converter (right-side) to right side of vehicle and secure. [Note: For illustration purposes, the installation position is shown with the engine removed.To loosen nuts (arrow) securing catalytic converter (A) to exhaust manifold on right side, use articulated wrench, 12 mm T40220.Attach a nut loosely to catalytic converter (right-side) to prevent it from dropping.]
50. Remove bolt (1) for starter.
51. Remove bolt (4), but do not remove starter. [Note: (Items 2 ... 3) can be disregarded.]
52. Remove remaining engine/gearbox securing bolts (3 … 6).
53. Detach gearbox from engine and lower carefully using engine and gearbox jackV.A.G 1383 A.

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