Removing gearbox - vehicles with 8-cyl. 4.2 ltr. TDI engine — AUDI

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• Special tools named: T40091/3, T40091/2, T40093/5, T40093/4, T40058

Don't miss

• (Arrows) can be disregarded.
• Take up weight of engine but do not lift. — Remove rear propshaft Transfer box and final drives39.
• Do not bend or kink the selector lever cable.
• (Item 3) can be disregarded.
• Place a piece of cloth below connection point to catch escaping ATF.Rules for cleanliness when working on the gearbox.

📋 Procedure

1. Remove particulate filters (left and right) Engine, mechanics26.
2. Remove catalytic converters (left and right) Engine, mechanics26.
3. Remove coolant pipes (rear left) Engine, mechanics19.
4. Remove air cleaner housings (left and right) Injection and glow plug system23.
5. Remove alternator Electrical system27.

6. Slacken bolt (1) and remove bolt (2) with nut.
7. Move coolant pipe (rear right) clear at engine lifting eye (rear right). [Note: (Arrows) can be disregarded.]
8. Pull off bonnet seal (1) on both sides in direction of (arrow).
9. Set up support bracket10 - 222 A with connecting pieces T40091/3, adapters 10 - 222 A /22 and 2 threaded spindles (1) from lifting tackle3033 on wing mounting flanges, as shown in illustration.
10. Engage hooks of threaded spindles (1) from lifting tackle3033 in engine lifting eyes (rear left and right).
11. Attach remaining parts of support bracket10 - 222 A as shown in illustration. Set up supports 10 - 222 A /19 on metal flanges of longitudinal members.
12. Insert support T40091/2 with slide T40093/5 into the two connecting pieces T40093/4.
13. ⚠ Secure support T40091/2 using the retaining pins and split pins of the connecting pieces T40093/4. — Engage hook10 - 222 A /10 in engine lifting eye (front right).
14. Take up some of the engine's weight by tightening the 3 spindles evenly.
15. ⚠ Take up weight of engine but do not lift. — Remove rear propshaft Transfer box and final drives39.
16. Remove transfer box Transfer box and final drives39.
17. Remove bolts (3).
18. Loosen bolt (1) and detach heat shield (2) for selector lever cable.
19. Use removal lever80 - 200 to press ball head (2) on selector lever cable off gearbox selector lever.
20. Pull off retaining clip (1) and detach selector lever cable from gearbox. [Note: Do not bend or kink the selector lever cable.]
21. Remove bolts (2) and detach support bracket for selector lever cable.
22. Remove bolts (arrows) on left and right and remove brackets for catalytic converters.
23. Remove bolts (1) and (2) and detach bracket for turbocharger (left-side). [Note: (Item 3) can be disregarded.]
24. Remove bolts (1) and (2) and detach bracket for turbocharger (right-side).
25. Remove starter Electrical system27.
26. Move electrical connector (2) clear at bracket (5).
27. Remove bolts (1) and (4) and nut (3).
28. Detach bracket and remove centre hex stud underneath bracket.
29. Unplug electrical connectors (1 … 3) at gearbox. [Note: Place a piece of cloth below connection point to catch escaping ATF.Rules for cleanliness when working on the gearbox.]
30. Remove bolts (1) and (2) and detach ATF lines from gearbox.
31. Seal off open lines and connections with clean plugs from engine bung setVAS 6122.
32. Insert guide stud of adapter T40058 as follows:
33. To slacken bolts for torque converter, use adapter T40058 to counterhold or turn crankshaft.
34. ⚠ Irreparable damage can be caused if the camshaft timing chains slip.Only turn crankshaft in the direction of engine rotation (arrow). — Detach cover (1) towards the front.
35. Unscrew the 6 bolts (arrows) on the torque converter through the opening for the removed starter (turning the crankshaft 120° in direction of engine rotation each time).
36. Remove bolts (3 … 6) and (10, 11) securing gearbox to engine. [Note: Bolt (7) should remain screwed in hand-tight.]
37. Set up gearbox support3282 on engine and gearbox jackV.A.G 1383 A.
38. Place adjustment plate3282/49 on gearbox support3282 as shown in illustration.
39. Align arms of gearbox support according to holes in adjustment plate.
40. Attach support elements as illustrated on adjustment plate.
41. Place engine and gearbox jackV.A.G 1383 A with gearbox support3282 underneath gearbox. [Note: The arrow symbol on the adjustment plate points in the direction of travel.]
42. Align the adjustment plate parallel to the gearbox.
43. Secure support to tapped hole on rear of gearbox using bolt M10x20 (arrow).
44. Fit side supports at oil pan flange on left and right as shown in illustration.
45. Raise gearbox slightly.
46. Remove the last engine/gearbox securing bolt.
47. Press gearbox off engine and at the same time press torque converter away from drive plate (arrow).
48. Lower gearbox carefully with engine and gearbox jackV.A.G 1383 A.
49. ⚠ If the torque converter becomes dislodged, the drive lug on the ATF pump may be damaged irreparably when fitting the support bridge30 - 211 A. — Secure torque converter in gearbox with support bridge30 - 211 A to prevent it dropping out.

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