Removing gearbox - vehicles with 3.2 ltr. MPI engine: Audi TT Mk2

🧭 Before you start

Fits: Audi TT Mk2 (8J, 2006–2014)

• Opens: brake fluid
• Special tools named: T40093/3, T40091/1, T40091/3, T40093/4, T40091/2, T40093/5

Don't miss

• (Item B) can be disregarded.
• Do not operate clutch pedal after disconnecting pipe/hose assembly. — Unplug electrical connector (1) for reversing light switch F4.
• Illustration shows left side of vehicle.
• Make sure you do not damage surface coating on drive shafts.
• Mark position of flexible coupling and bevel box flange in relation to one another.

📋 Procedure

1. ⚠ When disconnecting the battery there is a risk of serious damage to electronic components:Observe the correct procedure for disconnecting the battery. — With ignition switched off, disconnect battery earth wire (arrow)Electrical system27Battery; Disconnecting and connecting battery.
2. Completely remove air cleaner housing 24Air cleaner; Exploded view - air cleaner housing.
3. Detach line (1) from air cleaner bracket (2).
4. Remove bolts (arrows) and remove air cleaner bracket.
5. Detach securing clip (3) for gear selector cable from gearbox selector lever (1) and pull cable off pin (arrow).

6. Detach securing clip (1) and pull cable end-piece off pin.
7. Detach securing clip (2) and pull cable end-piece off gate relay lever.
8. Pull locking mechanism forwards in direction of (arrow 1) onto stop and then turn to left in direction of (arrow 2) to lock.
9. Then press gate relay lever forwards (in direction of (arrow 3)).
10. Detach cable support bracket from gearbox (arrows); then move to one side and tie up together with selector cables.
11. Using hose clamp3094, clamp off supply hose to master cylinder. [Note: Clamping off the plastic supply hose with the hose clamp3094 will cause a permanent deformation.However, this does not damage the supply hose.After removing the hose clamp3094, the supply hose must be returned to its original shape.] [Note: In the following steps make sure that no brake fluid escapes onto the starter or onto the gearbox below. If this does happen, clean the affected area thoroughly.]
12. Pull clip (arrow) out as far as stop.
13. Pull plastic pipe or pipe/hose assembly (A) out of bleeder connection for clutch slave cylinder and seal end of pipe. [Note: (Item B) can be disregarded.]
14. ⚠ Do not operate clutch pedal after disconnecting pipe/hose assembly. — Unplug electrical connector (1) for reversing light switch F4.
15. Unscrew earth wire (2).
16. Then remove upper securing bolt from starter located below earth wire (2).
17. Unplug electrical connector (3).
18. Push cover (4) to rear.
19. Disconnect electrical wire (arrow) from starter and move clear.
20. Unscrew top engine/gearbox securing bolts (arrows).
21. Secure bracket T10338 to vacant tapped hole at rear left of engine.
22. Set up support bracket10 - 222 A on wing mounting flanges using the following equipment:
23. Hook spindle10 - 222 A /11 with shackle10 - 222 A /12 onto engine lifting eye (right-side).
24. Attach hook10 - 222 A /10 to bracket T10338.
25. Partly take up weight of engine/gearbox assembly via the spindles.
26. Assemble supports T40093/3 (2x) with adapters T40093/3-2 for left side and T40093/3-3 for right side.
27. Disconnect earth wire from longitudinal member (left-side).
28. Remove securing bolt for front section of longitudinal member on left and right.
29. Bolt adapter T40093/3-2 (left-side) and T40093/3-3 (right-side) to longitudinal members (arrow), using the bolts removed previously. [Note: Illustration shows left side of vehicle.]
30. Insert square bars T40091/1 into connecting pieces T40091/3 and supports T40093/3 as illustrated.
31. Fit connecting pieces T40093/4 onto square bars.
32. Insert support T40091/2 with slide T40093/5 into the two connecting pieces T40093/4.
33. ⚠ Accidents can be caused if parts of the support bracket are not correctly secured.Secure support T40091/2 using retaining pins and split pins of the connecting pieces T40093/4.Secure connecting pieces and supports using clamping bolts. — Attach spindle10 - 222 A /11 to slide and engine lifting eye.
34. Take up weight of engine/gearbox assembly by tightening the 3 spindles evenly.
35. Remove both front wheels.
36. Release fasteners (1 ... 4) and remove centre noise insulation.
37. Remove noise insulation (left and right) (arrows).
38. Remove noise insulation frame (arrow)General body repairs, exterior50Lock carrier; Exploded view - lock carrier.
39. Remove nut (3) and detach bracket (2) for wiring harness.
40. Remove starter securing bolt (1) and detach starter.
41. Unplug electrical connector (1) at oil level and oil temperature sender G266.
42. Unclip bracket (2) for electrical wiring leading to oil level and oil temperature sender G266 at subframe.
43. Remove bolts (arrows) for exhaust pipe bracket.
44. Remove bolts (2) and (3).
45. Fix position of subframe to avoid unnecessary wheel alignment Running gear, axles, steering40Subframe; Securing subframe.
46. Remove subframe Running gear, axles, steering40Subframe; Removing and installing subframe with steering rack.
47. Unbolt heat shield for drive shaft (right-side) from bevel box (arrows).
48. Unbolt drive shaft (left-side) from flange shaft on gearbox.
49. Unbolt drive shaft (right-side) from flange shaft on bevel box.
50. Tie up drive shafts with cable ties. [Note: Make sure you do not damage surface coating on drive shafts.]
51. Remove bolts (arrows) and detach bracket for bevel box.
52. Mark position of flexible coupling and bevel box flange in relation to one another.
53. Unbolt propshaft with flexible coupling from bevel box (arrows) (counterhold triangular flange with suitable lever).
54. Push engine/gearbox assembly forward slightly (towards front end) and then pull propshaft off bevel box. [Note: If seal is damaged propshaft must be renewed.]
55. ⚠ The seal (arrow) in the propshaft flange can be damaged.Push propshaft towards the rear and to the right as far as possible. — Tie up propshaft.
56. Remove bolt (arrow) from above bevel box.
57. Remove bolts (arrows) on gearbox mounting.
58. By adjusting spindles on support bracket10 - 222 A, lower gearbox by distance (a).
59. Unbolt gearbox bracket from gearbox (arrows).
60. Pull off securing clip (arrow) and remove gate relay lever (1).

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