Removing gearbox - vehicles with V8 engine: Audi A6 C5

🧭 Before you start

Top-side work clears the expansion tank, Lambda wiring and air cleaner housing and loosens the manifold nuts. Underneath, the noise insulation, drive shafts, exhaust front sections and propshaft are removed or tied aside, the gearbox is supported and its mountings removed, then raised to reach the bottom bolts. Remaining bolts come out except one, the selector rod linkage, reversing light switch, speed senders and selector shaft lever are released, the slave cylinder is pulled back and tied up, and the oil lines unbolted and plugged. The gearbox support is fitted and secured, the last bolt removed, and the gearbox drawn off its dowel sleeves and lowered.

Fits: Audi A6 C5 (4B)

Don't miss

• Do not damage the selector rods while raising the gearbox to reach the bottom bolts.
• Tie up the slave cylinder with lines connected and do not depress the clutch pedal afterwards.
• Plug the oil line holes as soon as the lines come off.
• Give the Lambda probe connectors enough slack when the front exhaust pipes come away.
• Check drive shaft clearance when lowering the gearbox.

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

📋 Procedure

1. ⚠ Vehicles with telematics: activate service mode of telematics control unit before disconnecting battery Radio, telephone, navigation system01Adaption. — Refer to coding on vehicles with encoded radio/radio navigation system (RNS); obtain coding if necessary.
2. Switch off ignition and remove ignition key.
3. Remove cover above battery (arrows).
4. Disconnect earth wire (arrow) at battery.
5. Unbolt coolant expansion tank (3)(arrows).

6. Unplug electrical wiring leading to coolant shortage indicator switch F66 at expansion tank (bottom) and move expansion tank clear to one side (with coolant hoses (1) and (2) attached).
7. Remove electrical connector (arrow) for Lambda probe from retainer on bulkhead (left-side), unplug connector and move wiring clear.
8. Guide wiring downwards to Lambda probe.
9. Loosen nuts accessible from above at connection between exhaust manifold and front exhaust pipe.
10. Remove bolts (arrows).
11. Remove air duct (1).
12. Detach air cleaner cover.
13. Unplug electrical connector (3) at air mass meter G70.
14. Disengage activated charcoal filter solenoid valve 1N80(item 2) at air cleaner housing.
15. Remove hose (1) for secondary air pump (turn to the left and disconnect).
16. Remove air intake hose at intake connecting pipe.
17. Disconnect vacuum hose (front right) from engine.
18. Unscrew bolt (arrow).
19. Take out air cleaner housing together with air mass meter and air intake hose.
20. Remove electrical connector (arrow) for Lambda probe from retainer on bulkhead (right-side), unplug connector and move wiring clear.
21. Guide wiring downwards to Lambda probe.
22. On vehicles fitted with auxiliary heater, remove screws (arrows) securing exhaust pipe of auxiliary/ additional heater to noise insulation.
23. Release fasteners (arrows) and detach noise insulation.
24. Detach bracket (arrow) for noise insulation.
25. Unbolt heat shield from gearbox above drive shaft (left and right) (arrows).
26. Unbolt both drive shafts from flange shafts (left-side drive shaft (1) shown in illustration).
27. Unscrew nuts (arrows) securing exhaust manifold to front exhaust pipe (left-side).
28. Unscrew nuts (arrows) securing exhaust manifold to front exhaust pipe (right-side).
29. Unscrew bolts (1) and (2) and remove bracket for exhaust system on gearbox.
30. Unfasten clamps (1) and (2) on exhaust system and slide clamps towards rear. [Note: The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10 ° – otherwise it can be damaged.]
31. Detach front exhaust pipes together with catalytic converters and Lambda probes. [Note: Ensure electrical connectors for Lambda probes have sufficient clearance.]
32. Unbolt heat shield for propshaft (arrows).
33. Unbolt propshaft (1) from gearbox and rest it on heat shield (2).
34. Secure propshaft to fuel line bracket (3) with wire (arrow).
35. Support gearbox using engine and gearbox jackV.A.G 1383 A with a suitable piece of wood (1).
36. Raise gearbox slightly to remove gearbox supports.
37. Unscrew bolts (1) and (2) and detach gearbox supports (both sides) from gearbox and subframe together with bonded rubber mountings.
38. Raise gearbox further in order to remove bottom bolts (arrows) securing engine to gearbox. [Note: Take care not to damage the selector rods when raising the gearbox further.]
39. Lower gearbox again slowly.
40. Remove remaining engine/gearbox securing bolts from below, but leave one bolt in place to hold gearbox.
41. Tie up drive shafts to the rear.
42. Unbolt connecting rod (2) for selector rod on right side of gearbox.
43. Remove hexagon socket head bolt (item 1) (8 mm) from push rod.
44. Unplug electrical connector (3) at reversing light switch F4.
45. Detach heat shield for engine speed sender on left side of gearbox.
46. Remove engine speed sender G28 from left side of gearbox (arrow) and lay aside.
47. Unplug electrical connector (arrow) on speedometer sender G22.
48. Unscrew nut (1) and detach selector shaft lever (2) from selector shaft.
49. Remove clutch slave cylinder (arrow), pull out towards rear and tie up with wire. Do not disconnect hoses/pipes. [Note: Do not depress clutch pedal after removing clutch slave cylinder.]
50. Unbolt oil lines from gearbox (arrows). Seal holes with plugs.
51. Detach bracket for oil lines (arrow).
52. Unbolt retainer for oil line at front of engine.
53. Tie up oil lines on right side.
54. To remove manual gearbox 01E (four-wheel drive), set up gearbox support3282 with adjustment plate3282/12 and place on engine and gearbox jackV.A.G 1383 A.
55. Align arms of gearbox support according to holes in adjustment plate.
56. Fit support elements (A). [Note: The positions of the support elements are shown on the adjustment plate3282/12 in schematic form (A) (the arrow (B) points in direction of travel).The adjustment plate can only be fitted in one position.]
57. Place engine and gearbox jack1383 A with gearbox support3282 underneath gearbox and position adjustment plate so it is parallel with gearbox.
58. Secure support elements (arrows) on left side of gearbox as shown in illustration.
59. Secure support elements (arrows) on right side of gearbox as shown in illustration.
60. Remove the remaining engine/gearbox securing bolt.

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