Gearbox removal — vehicles with a 4-cylinder diesel engine (Audi A4 B8)

You need to proceed as follows. Set the front wheels to the straight-ahead position. Turn off the ignition. Disconnect the battery. Carefully remove the engine cover. compartment in the "direction of the arrow" of the mounting bolts. Do not remove the engine cover by jerking or moving it to the side.

Remove the noise insulation screens by loosening the fastening elements "1...4" and "arrows".

Remove sound insulation "1" in the right wheel arch.

Unscrew the exhaust pipe nuts "arrows".

Disconnect the system. exhaust pipe in the area of the clamping sleeve "arrow" and remove the exhaust pipe.

Unscrew bolts "1" and "2" and remove the mounting bracket.

Place a pan under the engine and drain the coolant.

Remove the "arrow" seal. Remove individual parts "1, 2, 3" or the entire water drain box cover (depending on the release date).

Unscrew bolt "1" and remove the distribution block "in the direction of the arrow" from the tensioner. Disconnect plug connector "2" from the stretcher.

If present, remove spacer "3". To do this, unscrew bolts "1" and nuts "2".

For reinstallation, mark coolant hoses "1" and "2" and remove them from the pipes on the heater heat exchanger. Remove the coolant hoses from the front wall of the water drain box and route them to the engine. compartment. Additionally, the coolant hoses can be disconnected from the engine coolant pipes, allowing the coolant hoses to retain their installation. position on the front wall of the water drainage box. Disconnect the brake booster vacuum line connection from the front wall of the plenum box and remove the front wall of the plenum box.

Unscrew bolt "3" of the connecting rod of the water drainage box. "Pos. 1, 2" do not take into account.

Cars with a diesel particulate filter: Remove the air filter housing. filter. Unscrew nuts "1, 2, 3" of the turbocharger and tie up the filter.

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Unscrew the bolts "3...6" that secure the engine to the gearbox, which are accessible from above. Bolts "3" and "5" additionally secure the highway brackets. Secure these holders to the engine.

Unscrew the starter bolt "1". Remove the spacer sleeve "2" between the starter and the gearbox.

Install the "10-222 A" crossbar into the connection using the "10-222 A/1" posts and "10-222 A/3" adapters on the shock absorber strut cups on the left and right, as shown in the figure. Install the lead screws "10-222 A/11" into the rear engine lugs on the right and left.

Disconnect the cardan joint from the steering gear only when the front wheels are installed straight. wheels. Do not change the position of the steering wheel or steering gear; if necessary, secure the steering wheel with duct tape. Unscrew the "arrow" bolt of the universal joint. Press the steering gear cardan joint and move it fully upward.

Never lower the vehicle onto its wheels unless the subframe support, steering gear, or subframe cross-joint is properly installed. Remove bolt "1" of the power steering hydraulic line. Loosen the "arrow" bolts and remove the subframe crosspiece.

If present, unscrew the "arrow" bolts and remove the heat shield of the propeller shaft "A".

Secure the driveshaft against rotation using the "T10172" stop and the "T10172/5" adapter. For vehicles with a driveshaft mounted on the gearbox side, the rear final drive must be held in a similar manner.

Engage 6th gear by removing shift shaft "1" and shifting gear lever "2" forward in the "direction of the arrow".

Remove cover "1" under the gearbox "arrow".

Unscrew the 3 bolts "arrow" of the driven disk, to do this, rotate the clutch module accordingly through 120° in the direction of engine rotation.

The propeller shaft is bolted on the gearbox side: Unscrew the bolts connecting the propeller shaft and gearbox, while holding it from turning using the counter support "T10172" with "T10172/5". Move the propeller shaft toward the rear final drive housing; CV joints are movable in the axial direction. Tie the cardan shaft to the side.

The propeller shaft is inserted from the gearbox side: Remove the propeller shaft.

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Unscrew the arrow bolts and remove the heat shield of the right drive shaft. For better understanding of the montage. the position is shown with the gearbox removed.

Unscrew the left and right drive shafts from the shafts with the gearbox flange.

Vehicles with start-stop system: Disconnect the electrical connector of the neutral position sensor of the gearbox "G701" "1" and release the cable.

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Unscrew bolt "2" and tie the clutch slave cylinder to the side of the motorcycle. compartment. After removing the working cyl. do not press the clutch pedal. Unscrew nut "1".

Do not press the shift lever "1" with a crowbar or knock it down with a hammer. The gear shift lever must be removed using the "T40160" puller. Install the "T40160" puller and remove the "1" shift rod.

Remove the front engine mount by unscrewing bolts "1". Ignore items "2" and "3".

Unscrew bolt "3" of the starter from the engine side. Disconnect the starter from the gearbox and leave it in the mounting position. position. There is no need to disconnect the starter cables.

Install the engine and gearbox lift with gearbox mount "T40173" under the gearbox and secure with tension belt "1", as shown in the figure. When fixing the tension belt, make sure that the electrical wires on the gearbox are not pinched. Unscrew the tunnel cross member arrow bolts.

First, lower the gearbox using a tilting device by dimension "a." Dimension "a" = maximum 80 mm. Preliminarily, lightly tighten the lead screws of the "10-222 A" crossmember. To access the threaded pins with the vehicle raised, use the "VAS 5085" stepladder.

Crimp wire "A" onto the gearbox "arrows". Remove bracket "B" with plug connector "C" of exhaust gas temperature sensor 4 "G648" from the gearbox and secure it at the top.

Disconnect electrical connector "1" from gear detection sensor "F208" using puller "T40138" to release the electrical wire. Unscrew bolt "2" of the push rod. Bolt "3" is already unscrewed.

Unscrew the remaining bolts "7...10" connecting the engine/gearbox. Press the gearbox away from the engine approx. by 20 mm. Using the left running screw of the mounting device "T40173", tilt the gearbox to the right and guide it past the particulate filter "arrow A". In doing so, turn the gearbox slightly to the left. Then carefully lower the gearbox, guiding it past the steering mechanism and the final drive cover on the subframe "arrow B". When lowering, check that the cable is not pinched on the upper side of the gearbox. When lowering, ensure that the drive shafts move freely.

In case of replacement of the removed gearbox, it is necessary to move the following parts to the new gearbox: bracket "1" of the support bar of the system. exhaust system, tunnel crossmember with gearbox cushion and gearbox support.