Removing Transmission
Removing transmission on vehicles with 4.2 Liter V8 engine (S4), 0A3, 6-Speed All Wheel Drive M/T
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. approx. 100 Nm
2. approx. 70 Nm
3. approx. 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 10° - otherwise it can be damaged.
- Disconnect exhaust system at clamps - arrows -.
- Remove universal mounting V.A.G1359/2 from engine and transmission jack VAG 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 VAG 1383 A.
- First unscrew bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.
- Slowly lower rear cross member with engine and transmission jack VAG 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 60 mm. 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 10.2 mm [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 approx. 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
Installing transmission.