Removing gearbox, vehicles with petrol engine — AUDI

🧭 Before you start

Obtain the radio code, disconnect the battery and clear the plenum area, charge air hose and expansion tank. Clamp off the oil cooler hoses, release the selector cable and remove the starter and accessible bolts. Underneath, remove wheels, insulation, exhaust, subframe, drive shafts, propshaft, catalytic converter and rear engine support. Support the assembly, lower it to dimension (a), mount the gearbox on support 3282, pull it off the dowels and tilt it past the longitudinal member. Inspect and grease the crankshaft needle bearing.

Fits: VW Transporter T6 (7E)

Don't miss

• Fix the subframe position before removing it.
• Do not bend or kink the selector lever cable.
• Measure dimension (a) when lowering the engine and gearbox by approx. 115 mm.
• A damaged or blue-tarnished crankshaft needle bearing must be renewed.
• Grease the gearbox shaft end lightly, but not the splines.
• Attach the diagnosis log to a gearbox going back for analysis.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Check whether a coded radio is fitted. If so, obtain anti-theft code.
2. Remove outer lock carrier covers above headlights General body repairs, exterior63.
3. With ignition switched off, disconnect battery earth strap Electrical system27Battery; Disconnecting and connecting battery.
4. Then remove left and right plenum chamber bulkhead panels (arrows) from plenum chamber General body repairs, interior50Assembly overview - plenum chamber bulkhead.
5. ⚠ Observe notes concerning hose connections using screw-type clips 4-cyl. diesel engine (2.0 l common rail engine)21General notes on charge air system. — Open (2) clip and pull pressure hose off throttle valve control unit J338 together with throttle valve potentiometer G69 and motor for intake manifold flap V157(1).

6. Open clip (2) and remove pressure hose (1) leading to charge air cooler.
7. Release connector (1) and pull off.
8. Pull wiring harness (3) out of coolant expansion tank (2).
9. Remove bolts (4) from coolant expansion tank (2).
10. Remove return hose from coolant expansion tank. Seal coolant expansion tank and return hose with bungs from engine bung setVAS 6122.
11. Clamp off coolant hoses (1) and (2) using hose clamps to 25 mm3094 and disconnect hoses from gear oil cooler.
12. Route coolant hoses (1) upwards and tie-up.
13. Push locking device (2) of selector lever (4) forwards (arrow A) until it engages.
14. Remove selector lever cable (4) from selector shaft lever (arrow B).
15. Do not bend or kink selector lever cable (4).
16. If fitted, unclip breather line (3) with retainer (2).
17. Remove engine/gearbox connecting bolt (1).
18. Remove starter Electrical system27Starter; Removing and installing starter.
19. Remove engine/gearbox connecting bolt (2).
20. Release quick-release cover by turning it (arrow) and then pull it off.
21. Raise vehicle.
22. Remove front wheels.
23. Remove any noise insulation General body repairs, exterior50Noise insulation.
24. Remove exhaust system from subframe.
25. Remove subframe. First fix position of subframe Running gear, axles, steering40Repairing front suspension; Removing and installing subframe.
26. Detach left and right drive shaft from gearbox flange, and tie them up Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts.
27. Release right track rod ball joint from wheel bearing housing using ball joint puller T40010Running gear, axles, steering44Assembly overview - front wheel bearings. [Note: Lead sealing of tachograph sender G75 may only to be carried out by authorised specialist workshops Electrical system90.]
28. If present, disconnect connector (arrow) for tachograph sender G75.
29. Loosen bolts (1) of propshaft heat shield (2). Remove heat shield.
30. Remove propshaft Propshaft and rear final drive39.
31. Remove downstream catalytic converter 4-cylinder injection engine (2.0 l direct injection engine, turbocharger)26Emission control; Removing and installing downstream catalytic converter.
32. Remove rear engine support 4-cylinder injection engine (2.0 l direct injection engine, turbocharger)10Assembly mountings; Removing and installing assembly mountings.
33. Unscrew bolts (1 and 2).
34. Remove retainer (3).
35. Unscrew bolts (1) from steering rack, and tie up oil line (2).
36. Bolt on retainer (2) with bolts (1).
37. Remove protective caps for suspension struts.
38. Place adapter10-222A/23-1 behind suspension strut (arrow A) and on lock carrier at front (arrow B).
39. Secure adapter10-222A/3 and adapter10-222A/23-1 to support bracket10-222A.
40. Slightly take up weight of engine/gearbox assembly on spindle10-222A/10 with hook10 - 222 A /2.
41. Position engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931 under dual clutch gearbox and exert slight counter pressure.
42. Unscrew bolts (arrows A) from left assembly mounting.
43. Only when dual clutch gearbox is being replaced, unscrew assembly mounting from gearbox (arrow B). The third bolt is not visible in the figure.
44. Remove engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931 from under dual clutch gearbox.
45. Remove engine/gearbox connecting bolts (3), (5), (6) and (7).
46. Release wiring harness (1) from retainer (2).
47. Now step onto step ladderVAS 5085 to lower engine/gearbox assembly using adapter and spindle.
48. Using spindle and hook10 - 222 A /10 of support bracket10-222A, lower engine/gearbox by approx. 115 mm to dimension (a).
49. Pull cable support bracket towards rear and upwards out of dual clutch gearbox. [Note: Measure dimension (a) between lower side of longitudinal member (1) and bolting surface of engine/gearbox mounting (2).]
50. Only when dual clutch gearbox is being replaced, unscrew assembly mounting from gearbox (arrow B). The third bolt is not visible in the figure.
51. Unhook selector lever cable from cable support bracket when lowering dual clutch gearbox.
52. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931.
53. Align arms of gearbox support according to holes in adjustment plate.
54. Place engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931 with gearbox support3282 under vehicle.
55. Secure mounting (2) using one M10 bolt (1).
56. Insert pin (3) into dual clutch gearbox support.
57. Insert hook (1) into dual clutch gearbox support.
58. Insert pin (2) into dual clutch gearbox support.
59. Insert pin into dual clutch gearbox support.
60. Unscrew front bolt of assembly mounting, fit support, and tighten it.

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing and installing side member trim - Audi RS 4 – Audi
• Removing and installing seat pan cover and padding - seat pan with seat depth adjustment
• Separating seat pan cover and padding - seat pan with seat depth adjustment
• Removing and installing suction pipe
• Removing and installing starter - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine