Removing Transmission
Removing transmission on vehicles with 4.2 Liter V8 engine (S4), 0A3, 6 Spd. M/T AWD
Special tools, testers and auxiliary items required:
^ Support bracket 10 - 222 A
^ Shackle 10 - 222 A/12
^ Lifting tackle 2024 A
^ Hose clamps, up to diameter 25 mm 3094
^ Transmission support 3282
^ Adjustment plate 3282/38
Special tools, testers and auxiliary items required
Locating pins 3393:
Engine and transmission jack V.A.G 1383 A:
Removing
Note:
^ All cable ties which are released or cut open during removal must be installed in the same position when installing.
^ Heat insulation sleeves removed during removal of transmission must be installed in the same position when installing.
CAUTION:
^ Follow steps required when disconnecting battery.
- With the ignition switched off, disconnect battery ground (GND) strap.
- Pull off rear engine cover - arrows -.
- Pull off front engine cover - arrows -.
- Remove cover - 1 - on left side of engine compartment.
- Clamp off coolant hose - 1 - with hose clamp 3094 and disconnect hose at coolant expansion tank.
- Unbolt coolant expansion tank - 2 - - arrows -.
- Disconnect electrical wire leading to Engine Coolant Level (ECL) Warning Switch F66 at expansion tank (bottom) and move coolant expansion tank (with coolant hose - 3 - attached) clear to one side.
- If necessary, close off the connection with a suitable plug.
- Disconnect electrical connectors - 1 to 4 - from retainer at left of bulkhead.
- Disconnect electrical connectors - 1 -, - 3 - and - 4 -.
- Disconnect retainer at bulkhead.
- Disconnect heat insulation sleeve at wiring harness and move wiring harness clear.
- Move oxygen sensor probe wires clear (downwards).
- Remove cover - 1 - on right side of engine compartment.
- Remove air intake hose - arrows -.
- Disconnect connectors - 1 to 4 - from retainer at right of bulkhead.
- Disconnect electrical connectors - 2 - and - 4 -.
- Move oxygen sensor probe wires clear (downwards).
- Fix a shackle 10 - 222 A/12 to engine lifting eye (rear right).
Note:
^ - Item 1 - can be disregarded.
- Set up support bracket 10 - 222 A on wing mounting flanges.
- Remove eye of lifting tackle 2024 A.
- Re-insert pin - 1 - in center hole of lifting tackle and secure with split pin.
- Hook pin on lifting tackle 2024 A onto spindle of support bracket 10 - 222 A.
- Hook lifting tackle 2024 A into lifting eye at front of engine and into shackle 10 - 222 A/12 at rear.
CAUTION: Support hooks and locking pins on lifting tackle must be secured with retainers - arrows - in illustration.
- Take up weight of engine on spindle of support bracket, but do not lift.
- Unbolt both front wheels.
- On vehicles installed with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary/ additional heater to noise insulation.
- Release quick release fasteners - 1 -, unscrew bolts - 2 - and remove noise insulation.
- Unbolt bracket for noise insulation - arrows -.
- Unbolt bracket for wiring harness at engine support (right-side) - arrows -.
- Unscrew nuts - 1 - at bottom of engine mountings (left and right).
- If installed, unclip operating rod for vehicle level sender from lower transverse link - arrow -.
- Before slackening subframe mountings, use locating pins 3393 to check whether holes - 1...3 - are aligned.
CAUTION: If this is not the case, wheel alignment has to be performed after installing the subframe.
- First remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
- Lower subframe at the front.
- Unscrew lower engine/transmission securing bolts - arrows -.
- Temporarily secure subframe again. Temporary tightening torque:
1. approximately 100 Nm
2. approximately 70 Nm
3. approximately 70 Nm
CAUTION: Do not replace bolts yet or tighten to their final torque. This will be done when installing the transmission.
Note:
^ The flexible exhaust pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 100 otherwise it can be damaged
- Disconnect exhaust system at clamps - arrows
- Remove universal mounting V.A.G1359/2 from engine and transmission jack V.A.G 1383 A and place a wooden block - arrow - on the lifting column in its place.
- Support the rear cross member with engine and transmission jack V.A.G 1383 A.
- First unscrew bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.
- Slowly lower rear cross member with engine and transmission jack V.A.G 1383 A.
Note:
^ Do not lower the transmission too far. the distance between the rear cross member and the body (dimension - x -) must not be more than 60mm. Otherwise, the driveshaft joint and the flexible joint in the front exhaust pipe could be damaged. If necessary, tighten spindle of support bracket 10 - 222 A so that dimension - x - is not exceeded.
- Remove heat shields - arrow - for drive shafts (left and right).
- Unbolt drive shafts from transmission flanges.
Note:
^ Make sure you do not damage surface coating on drive shafts.
- Unscrew connecting rod - 2 - for selector rod.
- Disconnect push rod - 1 -; to do so, unscrew hexagon socket head bolt.
- Disconnect oxygen sensor probe wiring on transmission at the points marked with - arrows -.
Note:
^ In the illustration the engine/transmission assembly has been removed.
- Unscrew bolt - arrow - at bracket for front exhaust pipe (left-side).
- Unscrew nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
Note:
^ In the illustration the engine has been removed.
- Disconnect front exhaust pipe from exhaust manifold (left-side).
- Remove front exhaust pipe.
- Unscrew bolt - arrow - at bracket for front exhaust pipe (right-side).
- Unscrew nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.
Note:
^ In the illustration the engine has been removed.
- Remove front exhaust pipe.
- Unbolt heat shield for driveshaft - arrows -.
- Unscrew bolts at transmission/driveshaft flange.
- Slide driveshaft together towards rear final drive. The constant velocity joints can be moved axially.
- Allow driveshaft to rest on rear section of exhaust system.
- Unscrew two nuts - arrows - and Disconnect tunnel cross member.
- Unscrew nut - 1 - and pull transmission selector lever - 2 - off transmission selector shaft.
- Disconnect connector - arrow - for reversing light switch on right side of transmission and move wiring clear.
- Unbolt starter - 1 - - arrows - and pull it away from bell housing.
- Remove remaining engine/transmission bolts. Leave 2 bolts screwed in hand-tight.
- Unbolt bracket for front exhaust pipe (left-side) on transmission - arrows -.
- Drill a hole of 10.2mm diameter - arrow - in supporting element of transmission support 3282.
- Set up transmission support 3282 with adjustment plate 3282/38 for removing manual transmission 03A (All wheel drive) and place on engine and transmission jack V.A.G 1383 A.
Note:
^ The positions of the support elements - arrows - are shown on the adjustment plate in schematic form (the arrow points in direction of travel).
^ The adjustment plate can only be installed in one position.
- Align adjustment plate parallel to transmission and secure support elements - arrows -to left side of transmission.
- Align adjustment plate parallel to transmission and secure support elements - arrows -to right side of transmission.
- Remove 2 last engine/transmission bolts.
- Press transmission off dowel sleeves and lower carefully with engine and transmission jack V.A.G 1383 A just far enough to gain access to the clutch slave cylinder.
Note:
^ When lowering transmission, ensure hydraulic line to clutch slave cylinder is not damaged.
- Remove clutch slave cylinder - arrow - and secure with wire; do not open hydraulic system.
CAUTION: Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approximately 300 N.
- Lower transmission completely.
Note:
^ When lowering transmission, make sure there is sufficient clearance to drive shafts.
- If you will be installing a new transmission instead of the one removed, the transmission mounting has to be transferred to the new transmission - arrows -