Removing and installing gearbox Audi A4

Parts and consumables:

• Lubricant AUDI-G000100

Notes:

To remove the gearbox, the vehicle must be raised to the required height. In addition, a garage lift is required for this operation. The operations described below apply to a 5-speed manual transmission in front wheel drive vehicles.

Removing and installing gearbox Audi A4

1. Disconnect the negative (-) battery cable to remove the transmission.

Warning:

Observe the instructions in the section  Replacing the battery .

2. Remove the engine covers, refer to  Removing and Installing the Top Engine Cover / Underbody Guard / Subframe .

3. Remove the turbocharger retaining nuts.

4. Remove all engine/gearbox connecting bolts that are accessible from above.

5. Install the yoke and tie up the engine.

Warning:

The fuel supply line is under pressure! Cover with a thick cloth before opening the hose connection. Then relieve pressure by carefully disconnecting the hose.

6. Raise and place the vehicle on stands.

7. Parking heater models: Remove the bolts securing the parking / auxiliary heating outlet pipe to the lower engine cover.

8. Unscrew the mounting bolts and remove the lower engine compartment cover holder ( arrow ).

9. Remove the heat shield above the right drive shaft.

10. Remove the mounting bolts and remove the left and right covers ( arrows ) of the exhaust pipe.

11. Remove the front tunnel cross member ( 1 ).

12. Remove the downpipe ( 3 ) from the terminal sleeve ( 2 ).

13. Remove the heat shield ( 4 ) above the exhaust system.

14. Remove the engine/gearbox lower connecting bolts.

15. Flanged off both drive shafts and tie them to wire, refer to  Drive Shaft Removal and Installation .

Warning:

Take care not to damage the protective coating of the drive shafts when unscrewing.

16. Remove the starter, at the same time do not disconnect the cable from the starter. Secure the starter to the wire to the body.

17. At service stations, the checkpoint is fixed and supported by the VAG lift. If the specified lift is not available, move a garage lift with a wide wooden spacer under the checkpoint and slightly raise the checkpoint.

18. First unscrew the bolts ( 2 ) and then the bolts ( 3 ) on the tunnel cross member. Unscrew both nuts ( 4 ), remove the tunnel cross member.

19. Carefully lower the engine / gearbox lift so that the gearbox is visible. Remove the lift.

20. Remove the bolt ( A ) securing the rod to the gearbox and disconnect the shift joint from the axle.

21. Disconnect the push rod by unscrewing the socket head cap screw ( B ) at the transmission.

22. Remove the connector ( 1 ), if present, from the holder ( arrow ). Disconnect the connector and lay the cable aside.

23. Disconnect the connector ( A ) of the tachometer sensor and ( B ) of the reversing light on the left at the gearbox

24. Disconnect the engine speed sensor, if any, on the left of the gearbox ( arrow ) and move it to the side.

25. Remove the lower engine / gearbox connecting bolts, but not bolts ( A ) and ( B ).

26. Bring a suitable lift under the checkpoint and fix the checkpoint with an adjusting plate.

27. Remove the remaining engine / gearbox connecting bolts ( A ) and ( B ).

28. Press the gearbox away from the engine and slowly lower it down.

29. Installation of the gearbox. Before installation, check the clutch, refer to the section  Removing, installing and checking the clutch .

Note:

When replacing any gearbox-mounted parts or bolts, keep the following in mind: The gearbox housing is made of magnesium or aluminum. In accordance with this, certain installed parts are used, such as a cover, and bolts. If aluminum gearbox parts are installed on a magnesium alloy body, the latter will corrode. This also applies to the engine / gearbox flange mounting bolts. They have a special magnesium alloy coating for the gearbox housing. The sign of the gearbox made of magnesium alloy is the inscription "Mg AL 9 Zn 1" on the underside of the gearbox and in the area of ​​the oil filling plug.

30. Clean the splined connection of the input shaft and lightly lubricate with MoS 2   AUDI-G000100.

AUDI-G000100 grease

Warning:

The clutch disc should fit easily onto the gearbox input shaft. Remove excess grease.

31. Clean all threaded holes into which self-locking bolts are screwed with a tap to remove any sealant residue. Be sure to replace self-locking bolts and nuts with new ones.

32. Check the wear of the clutch release bearing, replace if necessary. If the plastic bearing has grooves deeper than 0.5 mm, the bearing must be replaced.

33. Lubricate the contact surface of the tappet at the clutch release bearing lever with a copper grease, for example, "Z381 351 TE".

34. Check if the centering sleeves for centering the engine / gearbox connection in the cylinder block are in place, insert if necessary.

35. Observe the correct position of the intermediate plate on the engine, if any.

36. Insert the gearbox horizontally into the clutch. If during installation the input shaft of the gearbox does not fit into the driven disk, turn the shaft by hand by the flange.

37. Install the clutch slave cylinder with holder. Using a pry bar, insert the cylinder so that the mounting bolt can be easily inserted. Tighten the bolt to  25Nm .

38. Reinstall the starter.

39. Install the lower bolts ( A ) to secure the engine to the gearbox and ( B ) to secure the starter.

40. Lower the engine / gearbox assembly.

41. Tighten the upper engine / gearbox mounting bolts to the specified torque.

42. Secure the tunnel cross member to the gearbox support ( 1 ).

43. Secure the tunnel cross member to the body. Screw in first the bolt (2) then the bolt ( 3 ).

44. Tighten the 3 bolts that secure the engine to the gearbox from below to 45Nm.

45. Reinstall the gear shift rod. Secure it with a torque of 20 Nm.

46. Install the push rod and secure it with a torque of 40 Nm.

47. Install the drive shafts and shaft shield, refer to the Drive Shaft Removal and Installation section  .

48. Dock all previously disconnected connectors.

49. When making electrical connections, make sure that all clamps removed or cut off during removal are reinstalled in their original positions.

50. Install the exhaust pipe heat shield. Install the downpipe and install the exhaust system.

51. Check the shift actuator adjustment, refer to the Shift Actuator Adjustment section  .

52. Check the oil level in the transmission, refer to the section  Checking the oil level in the manual transmission .

53. Connect the negative (-) battery cable. Observe the instructions in the section  Replacing the battery .

The article is missing:

• High-quality photos of repair

Source:  http://audi-a4.5go.com/html/6_2.htm