Gearbox removal — vehicles with 4-cylinder diesel engine (Audi Q5-8R)

Set the front wheels to the straight-ahead position. Turn off the ignition. Disconnect the battery.



Carefully remove the engine compartment cover "in the direction of the arrow" from the mounting bolts. Do not remove the engine cover jerkily or by shifting it to the side. Remove the noise insulation screens "1" and "2". Remove the noise insulation on the right and left "1" in the wheel arch.



Unscrew the exhaust pipe nuts "arrows".



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





Unscrew the threaded connection "1".



Remove the spacer. Remove the air filter housing.



Unscrew nuts "1,2,3" of the turbocharger and tie up the filter.



Unscrew bolts "2...6" connecting the engine/gearbox. Bolts "3" and "5" additionally secure the line brackets. Secure these brackets to the engine. Bolt "2" secures the starter to the gearbox. There is a spacer sleeve "arrow" between the starter and the gearbox.





Install the tensioner and hang it with the tension belt "T10038" on the engine eye, as shown in the figure. Tighten the tension belt.



Risk of damage to the wound Airbag spring. Disconnect the universal joint from the steering gear only when the front wheels are installed straight. Do not change the position of the steering wheel and steering gear any further; if necessary, secure the steering wheel with insulating tape. Unscrew the bolt "arrow" of the universal joint. Press the universal joint of the steering gear and move it completely upwards.



Unscrew nut "1" of the hydraulic oil pressure line of the power steering. Risk of damage to chassis components. Never lower the vehicle onto its wheels unless the subframe support, steering gear or subframe cross-joint are properly mounted. Supporting the vehicle on the subframe or subframe struts (for example, on a mobile jack) not allowed! Unscrew the "arrow" bolts and remove the subframe spacer crosspiece.





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



If present, disconnect plug connector "2" of engine speed sensor "G28" and release the electrical wire on the gearbox. Ignore "Pos. 1".



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





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



Unscrew the "arrow" bolts and remove the heat shield of the right drive shaft.



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



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





Remove bolts "1" and "3".



Disconnect the "arrow" electrical connector of the "F208" gear detection sensor using the "T40138" puller and release the electrical wire.



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 screw "2" and remove the clutch slave cylinder from the gearbox, removing the tube from the bracket. Tie the slave cylinder to the side of the engine. Risk of damage to the clutch slave cylinder. After removing the clutch slave cylinder, do not press the clutch pedal. Unscrew nut "1".



Risk of damage to the gearbox shift shaft. Do not press the gearbox shift shaft "1" with a crowbar or knock it down with a hammer. Install the "T40160" puller and remove the gearbox lever "1".



Install a device for filling and pumping out oil under the disconnection point.



Unscrew the bolts "arrows", disconnect the hydraulic line "1" from the steering gear and put it aside. To prevent contamination, close the disconnected lines and pipes on the intercooler with a clean plug from the plug kit for the "VAS 6122" engine.



Unscrew bolt "1" of the starter. Disconnect the starter from the gearbox and leave it in the mounting position. It is not necessary to disconnect the starter cables. Unscrew the remaining bolts "7 - 10" connecting the engine to the gearbox. Install the tilter with the mounting bracket "T40173" under the gearbox and secure it with harness "1", as shown in the figure. When securing the harness, make sure that the gearbox electrical wires are not pinched.



Unscrew the bolts of the tunnel crossmember "arrow". Press the gearbox away from the engine and carefully lower it using a tilter. When lowering, check that the cable is not pinched on the upper side of the gearbox. When lowering, monitor the free play of the drive shafts.



In case of replacement of the removed gearbox, it is necessary to reinstall the following parts on the new gearbox. Bracket "1" of the exhaust system support bar. Tunnel cross member with gearbox cushion and gearbox support.



If necessary, remove the clutch module.

Installation

Note: Replace bolts tightened with a tightening angle. Aluminum bolts for fastening the engine to the manual transmission may be used twice. Replace self-locking nuts and bolts, as well as sealing rings, gaskets and sealing cuffs. Hose nipples, air ducts and hoses must be cleaned of oil and grease before installation. Use clamps of the appropriate series to secure all hose connections. To ensure reliable fastening of the air boost hoses to the nipples, treat the threaded connections of already used clamps with a rust remover. During installation, all cable ties must be placed in their original places.

Tightening torques when installing the gearbox

Install the gearbox on the gearbox bracket "T40173" and secure with harness "1", as shown in the figure. Check the primary shaft at the installation site in the flywheel disk "arrow" for signs of running-in. If necessary, replace the flywheel disk needle bearing.



If necessary, install the clutch module. Before connecting the engine and gearbox, perform the following preparatory actions. Insert the mounting device "T40169" from below into the gearbox housing and install the clutch module, as shown in the figure. The mounting device "T40169" must enter the semicircular groove "1" and additionally into the inspection hole "2". In order to find the inspection hole, it is necessary to turn the clutch module. Insert the mounting device bolts into the hole on the gearbox housing.



Install the "T40170" transport protection from below under the gearbox housing and attach it to the shaft with flange "1".



Check the presence of centering bushings "A" of the engine and gearbox in the cylinder block, insert bushings if necessary. Ignore pos. "1...10". Raise the gearbox so that the clutch slave cylinder can be installed. Tighten bolt "2".



If necessary, check for reuse and mark the aluminum bolts "2...10" connecting the engine and gearbox. Attach the engine to the gearbox and tighten the bolts "7...10" connecting the engine/gearbox. Install the starter and screw in bolt "1" by hand from the engine side.

Attach bracket "B" with plug connector "C" of exhaust gas temperature sensor 4 "G648" to the gearbox. Attach electrical wire "A" to the gearbox "arrows".



Install gearshift lever "2" as follows. Gearshift lever "2" can be installed on gearshift shaft "1" only in one position (notch in gear ring "arrow"). Tighten bolt "2" of gearshift lever.



Tighten the shift fork rod "1". Tighten the connecting rod "3". Fit the connector "2" of the gear detection sensor "F208". Remove the harness "T10038".



Continue lifting the gearbox and tighten the bolts of the tunnel crossmember "arrow". Remove the tilter with the mounting bracket "T40173" from under the gearbox.



Remove the tensioner. Unscrew the upper starter bolt "2" with the spacer sleeve between the starter and the gearbox "arrow".



Tighten the remaining bolts "1...6" of the engine/gearbox connection.

Vehicles with start-stop system: Connect the connector of the neutral position sensor of the gearbox "G701--1".

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Screw the cardan joint to the steering gear.



Screw the drive shafts on the right and left to the flange shafts of the gearbox.



Install the drive shaft heat shield.



Clutch module to driven disc bolt tightening sequence

Remove the transport fastening "T40170" and the mounting device "T40169". Engage 6th gear by removing the shift shaft "1" and shifting the gearbox lever "2" forward in the "direction of the arrow".



The next stage of work is absolutely necessary to ensure uniform contact with the driven disk without skewing. Rotate both front wheels in one direction so that the clutch module makes 1 full revolution. The control hole "arrow" should be visible again in the recess of the gearbox housing.

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Tighten the clutch module bolts on the driven disc as follows: Use only new bolts Tighten the bolts with a 16 mm ring spanner "V.A.G 1332/14". Screw in the first bolt "arrow" all the way (2 Nm).



Rotate the clutch module by means of the front wheels by 120° in the direction of engine rotation and tighten the second bolt by hand (2 N·m). Rotate the clutch module again by 120° in the direction of engine rotation. Screw in and tighten the third bolt. Now tighten the 2 remaining bolts. Installation is in the reverse order, while taking into account the following. Install the particulate filter and the exhaust pipe. Install the air filter housing. Install the power steering lines. Check the oil level in the manual transmission. Install the subframe crosspiece. Install the noise insulation screens. Install the strut. Pay attention to the work on installing the battery.

Tightening torques (Nm)

Note: The tightening torques given are valid for lightly greased, phosphated or oxidised nuts and bolts. The use of additional lubricants, such as motor or transmission oils, is permitted, with the exception of graphite-containing lubricants. Do not use degreased parts. The tightening torque tolerance is ±15%.

Bolts and nuts
	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Heat shield of the cardan shaft - tightening torque

Tighten the drive shaft heat shield arrow bolts to 23 Nm.

Mounting a 2.0L TDI engine to a manual transmission

POS.	Bolt	Nm
1(1)	M10x50 (2)	65
2(3)	M12X100 (4)	30 + 90°
3(5), 6	M12x75 (4)	30 + 90°
4,5(5)	M12x120 (4)	30 + 90°
7...9	M1 0x75 (4)	15 + 90°
10	M12x50 (4)	30 + 90°
A	Centering bushings

• (1) Additionally secures the starter.
• (2) The steel bolt is not replaceable.
• (3) Additionally secures the starter; with an additional spacer sleeve between the starter and gearbox.
• (4) Check the reusability of aluminum bolts and replace if necessary.
• (5) Additionally secures the electrical cable bracket.

Aluminum bolts "2...10" are allowed to be used no more than 2 times. Therefore, after the first use, mark such bolts with two notches "X" "arrow" with a cutter.



To avoid damaging the bolts when notching, do not clamp them in a vice. Insert the bolt as shown in the picture into a 14 mm socket with a 1/2 inch driver, which can then be clamped in a vice. Do not reuse bolts marked with an "X". Steel bolt "1" can be reused.