Transmission, 8-Cylinder FSI, Audi RS4, Removing
Transmission, 8-Cylinder FSI, Audi RS4, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Transmission Support (3282)
• Adjustment Plate (3282/38)
• Testing Mandrel (3393)
• Engine/Transmission Jack (V.A.G 1383 A)
• Fender Liners (T40045)
• Drill bit dia. 10.2 mm
• Screws M10x20 (qty. 2)
• Copper Grease (Z 381 351 TE)
• Grease For Clutch Disc Shaft Splines (G 000 100 )
Removing
• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.
• Heat shield sleeves and heat shields removed during removal should be placed in the same location when installing.
- Raise and secure luggage compartment floor covering.
CAUTION!
Heed appropriate instructions for battery disconnection.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Pull off the hood seal at the lock carrier and at the fender edges.
- To prevent damage to bolted flanges of fender when using Engine Support Bridge (10-222 A), insert Fender Insert Pads (T40045) on both sides between bolted flange of fender and web plate lying beneath.
- Set Engine Support Bridge (10-222 A) onto bolted flanges of fender.
- Connect both spindles with rear engine lifting eyes.
- Take up weight of engine on support bar spindles a little, but do not lift.
- Remove both front wheels.
- Loosen quick-release connectors - 1 -, remove screws - 2 - and remove noise insulation.
- Remove noise insulation bracket - arrows -.
- Remove wiring harness bracket at right of engine bracket - arrows -.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Disconnect electrical harness connector - 2 - at Left Front Level Control System Sensor (G78).
• Disregard - 1 -.
- Before loosening subframe, you must check whether Testing Mandrel (3393) can slide completely into holes - 1 - and - 2 - in subframe - arrow -.
CAUTION!
If this is not the case, vehicle alignment must be carried out after installing subframe.
- First remove front bolts - 2 - and - 3 - at left and right subframe. Then remove bolts - 1 -.
- Lower front subframe.
- Remove lower engine/transmission bolts - arrows -.
- Initially re-tighten subframe. Initial tightening specification:
1. 110 Nm
2. 75 Nm
3. 75 Nm
CAUTION!
Bolts are replaced after installing transmission and tightened to final tightening specification.
• Do not bend the flex joint in the front exhaust pipe more than 10°, otherwise it will be damaged.
- Separate the exhaust system at the clamping sleeves - 1 - and - 2 -.
CAUTION!
Damage to the Engine Speed (RPM) Sensor (G28).
• Remove the Engine Speed (RPM) Sensor (G28) before removing the transmission.
• The Engine Speed (RPM) Sensor (G28) will otherwise get destroyed when the transmission is removed.
- Bend heat shield slightly to side.
- Remove bolt - arrow - at Engine Speed (RPM) Sensor (G28) at left on transmission.
- Lay Engine Speed (RPM) Sensor (G28) with heat shield aside.
- Place plunger of Engine/Transmission Jack (V.A.G 1383 A) with a block of wood inserted between - 1 - on lower crossmember.
- Support lower crossmember using Engine/Transmission Jack (V.A.G 1383 A).
- First remove bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.
- Slowly lower bottom crossmember with Engine/Transmission Jack (V.A.G 1383 A) until distance from lower crossmember to body is - x -.
• Dimension - x - = max. 60 mm
• Transmission must not be lowered further because driveshaft joint and wires on bulkhead could be damaged. If necessary, re-tighten Engine Support Bridge (10-222 A) spindles so that dimension - x - is not exceeded.
- Remove heat shield - arrow - for left and right drive axle.
- Remove drive axles from transmission flange shafts.
• Make sure drive axle protective coating is not damaged.
- Remove electrical connectors - 1 to 4 - from bracket on transmission.
- Disconnect electrical connector.
- Remove heat shield sleeve on wiring harness and expose individual wires.
- Remove bolts - 1 - and - 2 - and remove left front exhaust pipe strap.
- Remove nuts - arrows -.
- Remove left front exhaust pipe with primary and main catalytic converter.
- Remove left front exhaust pipe bracket on transmission - arrows -.
- Remove bolts - 1 - and - 2 - and remove right front exhaust pipe strap.
- Remove nuts - arrows -.
- Remove right front exhaust pipe with primary and main catalytic converter.
- Remove right front exhaust pipe bracket on transmission - arrows -.
- Remove both nuts - arrows - and remove tunnel crossmember.
- Remove driveshaft heat shield - arrows -.
- Remove bolts - arrows - at transmission/driveshaft flange.
- Push driveshaft toward rear final drive. CV joints can be moved axially.
- Tie driveshaft up to side.
- Disconnect electrical harness connector - arrow - at Back-Up Light Switch (F4) at right on transmission.
- Expose electrical wiring.
- Remove selector rod connecting rod - 2 -.
- Remove push rod socket head hex bolt - 1 -.
- Remove nut - arrow - and remove transmission shift lever from selector shaft.
- Expose upper oxygen sensor wiring on transmission.
- Remove bolts - 2 - and - 4 - at starter heat shield.
- Remove retainer nut - 3 - and bolt - 1 -.
- Remove starter from transmission case.
- Remove remaining engine/transmission bolts, 2 bolts remain installed hand-tight.
- Make a hole 10.2 mm in dia. - arrow - in Transmission Support (3282) support piece.
- Position Transmission Support (3282) for removing manual transmission 0A3 with Adjustment Plate ( 3282/38) and place on Engine/Transmission Jack ( V.A.G 1383 A).
• Support piece - arrows - is represented figuratively on adjusting plate, arrow points in direction of travel.
• Adjusting plate only fits in one position.
- Align adjustment plate parallel to transmission.
- Secure support pieces at left of transmission as shown in illustration. Tighten M10x20 bolt - right arrow - to 20 Nm.
- Secure support pieces at right of transmission as shown in illustration. Tighten M10x20 bolt - left arrow - to 20 Nm.
- Remove last 2 engine/transmission bolts.
- Press transmission out of alignment sleeves and carefully lower with Engine/Transmission Jack (V.A.G 1383 A) until clutch slave cylinder is accessible.
• When lowering the transmission, make sure the hydraulic line to the clutch slave cylinder is not damaged.
- Remove clutch slave cylinder - arrow -, do not open wiring system.
- Tie up clutch slave cylinder together with selector linkage.
CAUTION!
Do not press clutch pedal after clutch slave cylinder has been removed. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.
- Completely lower transmission.
• Pay attention to drive axle clearance when lowering.
- If the transmission removed is replaced, the transmission supports of the old one must be fitted to the new one - arrows -.
