Removing gearbox - vehicles with 4.2 ltr. FSI engine: Audi A5 / A4 B8

🧭 Before you start

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

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• 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.
• 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).
• Risk of violating emission legislation applying to USA models.Do NOT release hose clip (2). — Move air hose clear to one side (crankcase breather hose (2) remains connected). To do so, release hose clips (4) and clamps (arrows).
• (Arrow) can be disregarded.
• (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. Remove engine cover panel (arrows).
5. Loosen wheel bolts of front wheels, but leave wheels in place.

6. Raise vehicle.
7. Loosen fasteners (1 … 3) and remove noise insulation panels.
8. Remove bolt (1) for hydraulic fluid pressure line for power steering.
9. ⚠ 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 bolts (arrows) and detach subframe cross brace.
10. Remove nuts (arrows) securing front silencer (left-side).
11. Remove nuts (arrows) securing front silencer (right-side).
12. ⚠ 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).
13. Unplug electrical connectors (1) on steering rack and (2) for engine speed sender G28 and move electrical wiring clear.
14. Pull cover (1) off bottom of gearbox (arrow).
15. Remove 6 bolts (arrow) for drive plate. To access each bolt, turn both wheels so that clutch module turns 60° further.
16. Remove front wheels.
17. Detach noise insulation (1) from wheel housing (both sides).
18. If fitted, remove subframe shield (1) (left and right); to do so, unscrew bolts (arrows) and take out shield towards inside.
19. Remove nuts (arrows) and bolt (1) and press catalytic converter to right side. [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.]
20. Remove coolant pipe (rear) 19Coolant pipes; Exploded view - coolant pipes.
21. Remove air duct (arrow).
22. Unplug electrical connector (1) from air mass meter G70.
23. Disconnect vacuum line (3) leading to air pipe.
24. Press release tabs and disconnect crankcase breather hose (2) from air hose.
25. Slacken hose clips (4) and release clamps (arrows) to remove air hose with air mass meter G70.
26. ⚠ Risk of violating emission legislation applying to USA models.Do NOT release hose clip (2). — Move air hose clear to one side (crankcase breather hose (2) remains connected). To do so, release hose clips (4) and clamps (arrows).
27. Disconnect vacuum line (1).
28. Detach air cleaner (bottom section) and disconnect electrical connector (2) at variable intake manifold changeover valve N335 on rear of air cleaner.
29. Disconnect hose (3) leading to secondary air pump.
30. Disconnect coolant hose from radiator (2) and from coolant pipe (right-side) (1).
31. Remove bolts (1) and (2) and detach coolant hose (arrow).
32. Disconnect coolant pipe (right-side) from connection and move clear to one side.
33. Remove bolts (1) and (2) and detach coolant connection. [Note: (Arrow) can be disregarded.]
34. Working from above, remove bolt (2) for connecting rod. [Note: (Item 1) can be disregarded.]
35. Remove bolts (2 … 6) securing gearbox to engine (accessible from above).
36. If fitted, remove bolts (arrows) and detach heat shield (A) for propshaft.
37. Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool T10172 with adapters T10172/5).
38. Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.
39. Tie propshaft up to one side.
40. Remove propshaft Rear final drive39Propshaft; Removing and installing propshaft.
41. Remove bolt (2) and tie up clutch slave cylinder to side in engine compartment.
42. ⚠ Risk of damage to clutch slave cylinder.Do not depress clutch pedal after removing slave cylinder. — Remove nut (1).
43. ⚠ 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).
44. ⚠ 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.
45. Press universal joint off steering rack and push all the way up.
46. Remove bolt (1), press retainer off gearbox and swivel back towards rear (arrow).
47. Remove bolt (1) for starter.
48. Detach starter from gearbox but do not remove starter.
49. Remove remaining engine/gearbox securing bolts (7 … 11).
50. 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.
51. Remove bolts (arrows) for tunnel cross member.
52. Lower gearbox initially only by dimension (a) using engine and gearbox jackV.A.G 1383 A.
53. Remove bolts (arrows) and detach heat shield for drive shaft (right-side). [Note: The installation position is shown with the gearbox removed.]
54. Remove bolts (arrows) and detach heat shield for drive shaft (left-side). [Note: The installation position is shown with the gearbox removed.]
55. Unbolt drive shafts (left and right) from flange shafts on gearbox (arrows).
56. Disconnect electrical connector (1) for gear detector switch F208 using release tool T40138 and move wiring clear.
57. Remove bolt (2) for push rod. [Note: (Item 3) can be disregarded.]
58. Detach gearbox from engine and lower carefully using engine and gearbox jackV.A.G 1383 A.

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