Removing and installing gearbox Audi A4

Parts and consumables:

• Grease AUDI-G000100

Notes:

To remove the gearbox, the car must be raised to the required height. In addition, a garage lift is required to carry out this operation. The operations described below refer to the 5-speed manual transmission of front-wheel drive vehicles.

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

Warning:

Follow the instructions in section  Replacing the battery .

2 . Remove engine covers, refer to  Removing and Installing Upper Engine Cover/Under Engine Compartment Guard/Subframe .

3 . Turn out nuts of fastening of a turbocharger.

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

5 . Install the crosshead and sling the engine.

Warning:

The fuel supply line is under pressure! Before opening the hose connection, cover it with a thick cloth. Then relieve the pressure by carefully disconnecting the hose.

6 . Raise and place the car on stands.

7 . Models with parking heater: remove the bolts securing the parking/auxiliary heating outlet pipe to the bottom cover of the engine compartment.

8 . Turn away bolts of fastening and remove the holder of the bottom cover of an impellent compartment ( arrow ).

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

10 . Turn away bolts of fastening and remove the left and right covers ( arrows ) of an exhaust pipe.

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

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

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

14 . Turn out the bottom connecting bolts the engine/gearbox.

15 . Disconnect both driveshafts at the flanges and tie them on a wire, refer to the Removing and installing the driveshaft section  .

Warning:

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

16 . Remove the starter, but do not disconnect the cable from the starter. Attach the starter to the wire to the body.

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

18 . Remove first 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 until the gearbox is visible. Remove the lift.

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

21 . Disconnect the push rod by unscrewing the Allen screw ( B ) at the gearbox.

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

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

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

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

26 . Move a suitable lift under the gearbox and fix the gearbox 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 . Gearbox installation. Before installing, check the clutch, refer to the section  Removing, installing and checking the clutch .

Note:

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

30 . Clean input shaft spline and lightly lubricate with MoS ₂   AUDI-G000100.

Grease AUDI-G000100.

Warning:

The clutch disc should slide easily onto the gearbox input shaft. Remove excess lubricant.

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

32 . Check clutch release bearing for wear, 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 copper grease such as "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 . Check the correct position of the intermediate plate at the engine, if any.

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

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 . Install the starter.

39 . Screw in the bottom bolts ( A ) to mount the engine with the gearbox and ( B ) to mount the starter.

40 . Lower the engine/gearbox assembly.

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

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

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

44 . Tighten the bottom 3 bolts securing the engine to the gearbox with a torque of 45Nm.

45 . Establish into place draft of a gear change. Fasten it with a torque of 20Nm.

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

47 . Install the drive shafts and shaft shield, refer to  Removing and Installing the Drive Shaft .

48 . Connect all previously disconnected connectors.

49 . When laying electrical connections, make sure that all clamps removed or cut during dismantling are installed in their original places.

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

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

52 . Check the transmission oil level, refer to  Checking the Manual Transmission Oil Level .

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

The article is missing:

• High-quality repair photos

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