Withdrawal
1. Place the vehicle on jack stands so as to provide free access to the engine compartment, as well as unhindered work under the vehicle. The gearbox is removed downward.
2. Disconnect the wire terminal «masses» (-) from the battery and remove the fairing.
3. Remove the protective cover from the engine and disconnect the air intake 1 from the upper cross member of the front end (see illustration).
2.3. Disconnect the air intake 1 from the upper cross member of the front end
4. Remove the supply air duct 4 by disconnecting plug 2 of the canister purge valve, releasing the valve from the holder and disconnecting plug 3 of the mass air flow sensor (see illustration 2.3).
5. Remove cover 6 of the air filter (see illustration 2.3).
6. Unscrew bolts of fastening of a broad tank of system of cooling and shift it aside, without disconnecting hoses, the corresponding chapter see.
7. Disconnect the plugs of the lambda probes on the exhaust manifolds of the right and left heads and release their wires from the holders.
8. Unscrew the top nuts of fastening of reception pipes to final collectors, the corresponding chapter see.
9. Unscrew the upper bolts that connect the gearbox to the engine and are accessible at this moment.
10. Secure the motor with a hoist at the eyelets. In workshops, a special beam is used for this purpose, installed in the engine compartment.
11. Remove the front wheels and engine protection if they have not been removed before.
12. Remove the protective shields over the right and left drive shafts (see arrows in illustration).
2.12. Remove the protective shields over the right and left drive shafts (see arrows)
13. Disconnect the right and left drive shafts from the flanges on the gearbox by unscrewing the mounting bolts. Secure the disconnected drive shafts with wire to the body so that they do not sag.
14. Unscrew the bolt of the tachometer sensor on the left side of the gearbox and shift the sensor to the side, and also disconnect the speedometer sensor plug (see arrows B and A in the illustration).
2.14. Unscrew the tachometer sensor mounting bolt and move the sensor to the side, and also disconnect the speedometer sensor plug (see arrows B and A)
15. Disconnect the plug 1 of the selector, wring out the stopper 2 and disconnect the plug on the transmission wiring harness (see illustration).
2.15. Disconnect the plug 1 of the selector, wring out the stopper 2 and disconnect the plug on the transmission wiring harness
16. Unscrew bolts of fastening and remove a starter, the corresponding chapter see. Removing the starter is necessary to gain access to the torque converter mounting bolts.
17. Unscrew the three bolts that secure the torque converter through the hole in the starter seat. In order to bring the next torque converter mounting bolt into the hole, the engine should be turned 1/3 of a turn (see illustration).
2.17. Unscrew the three bolts that secure the torque converter through the hole in the starter seat
18. Disconnect the generator ventilation hose 1 and unscrew the bolt 2 of the transmission fluid circulation pipe holder (see illustration).
2.18. Disconnect the generator ventilation hose 1 and unscrew the bolt 3 of the transmission fluid circulation pipe holder
19. Place a container under the transmission fluid circulation pipes and disconnect the pipes 1 from the transmission fluid cooling radiator (see illustration). Plug the openings of the pipelines with suitable plugs.
2.19. Disconnect the pipelines 1 from the transmission fluid cooling radiator: 2 - starter mounting bot
20. Unscrew the bolt 3 of the transmission fluid circulation pipe holder (see illustration 2.19).
21. Remove, if necessary, the rear part of the exhaust system, see the relevant chapter.
22. Unscrew the mounting bolts (see arrows in illustration) and remove the propshaft guard B connected to the Torsen differential cover.
2.22. Unscrew the fastening bolts (see arrows) and remove the protective shield B of the cardan shaft
23. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines (see illustration).
2.23. Unscrew the bolts securing the cardan shaft 1 to the gearbox, lower it onto the shield 2 and additionally fasten it with a wire to the holder 3 of the fuel lines
24. Place a suitable support under the gearbox. In workshops, for these purposes, they use a special support VAG 1383A with a plate 3282/19, which ensures proper fastening of the box and allows it to maintain its horizontal position (see illustration).
2.24. Support VAG 1383A for removing the gearbox
25. Unscrew bolts of fastening and remove the right and left support of a suspension bracket of a transmission.
26. Unscrew bolts of fastening of the selector (see arrows in illustration) and move it to the side along with the wire. This operation is recommended to avoid damage to the selector.
2.26. Unscrew bolts of fastening of the selector (see arrows) and move it to the side along with the wire
27. Mark the mounting position of the gear shift rod support and remove the support by unscrewing the fastening bolts (see illustration).
2.27. Mark the mounting position of the shift rod support and remove the support by unscrewing the fastening bolts
28. Disconnect the tip of the gear shift cable from the selector using the 80-200 wrench (see illustration).
2.28. Disconnect the tip of the shift cable from the selector, using the key 80-200
29. Vehicles with a 6-cylinder TDI engine. Loosen bolt A behind the turbocharger a few turns and turn spacer B in the direction of the arrow (see illustration). In this position of the spacer, tighten bolt A.
2.29. Loosen bolt A behind the turbocharger a few turns and turn spacer B in the direction of the arrow
Attention! To remove the gearbox, it is necessary to lower the subframe by unscrewing the corresponding bolts of its fastening.
30. Unscrew on both sides the bolts 1 and 2 of the support brackets for fastening the rear part of the subframe, as well as the front bolts 3 (see illustration).
2.30. Unscrew from both sides the bolts 1 and 2 of the support brackets for fastening the rear part of the subframe, as well as the front bolts 3
Attention! The vehicle manufacturer recommends that before performing this operation, make sure, using a special tool, that the holes for bolts 1 and 2 are in line with each other. If this is not the case, a camber and toe check should be performed after the gearbox/subframe is installed (see illustration 2.30a).
2.30a. Checking the alignment of bolt holes 1 and 2 with AUDI-3393
After unscrewing the bolts, the rear part of the subframe is lowered by approx. 150 mm.
31. Unscrew the bottom bolts of fastening of reception pipes and disconnect them if it has not been made earlier.
32. Unscrew the remained bolts of fastening of a transmission to the engine and wring out a transmission from the engine. If necessary, use a pry bar to disconnect the torque converter from the drive plate (see illustration). The torque converter must remain in the gearbox. Make sure it doesn't fall out.
2.32. Unscrew the remaining bolts securing the gearbox to the engine and press the gearbox away from the engine
33. Tilt the gearbox by lowering its rear end by adjusting the support stop (see arrow in illustration).
2.33. Tilt the gearbox by lowering its rear end by adjusting the support stop (see arrow)
34. Make sure that all wires and pipelines are disconnected and nothing will prevent the gearbox from lowering on the support.
35. Lower the box on the support down and take it out from under the car.
Installation
The gearbox is installed in the reverse order of its removal.
Make sure the torque converter is properly positioned in the box and prevent it from falling out during installation.
36. Be sure to use the original bolts to attach the torque converter to the clutch drive disc. Otherwise, the torque converter will be damaged.
37. Screw in and tighten the bolts securing the gearbox to the engine (see illustration).
2.37. Screw in and tighten the bolts securing the gearbox to the engine
38. Top up, if necessary, the transmission fluid level.
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