4.2L FSI
Transmission, Removing
Remove Audi A5, 4.2L FSI transmission
• Through VIN 8T-8A-023117, the Audi A5, 4.2L FSI engine's transmission can only be removed together with the engine.
Special tools, testers and auxiliary items required
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Release Tool f/ Rev. Light Switch Conn. (T40138)
• Puller for Gear Shaft Linkage (T40160)
• Transmission Support (T40173)
• Jointed Socket, 12 mm (T40220)
• Engine/Transmission Jack (V.A.G 1383 A)
• Extractor (T40176)
Removing
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Position the front wheels so they are straight.
- Turn off the ignition and remove the key.
- Disconnect the ground (GND) cable - 2 - from the battery terminal.
- Remove the engine cover - arrows -.
- Just loosen the wheel bolts on the front wheels; do not remove the wheels.
- Lift the vehicle.
- Remove the noise insulation by loosening the fasteners - 1 through 3 -.
- Remove the bolt - 1 - for the power steering hydraulic fluid line.
The suspension components could be damaged.
Do not rest the vehicle on its wheels if the subframe, the steering gear or the subframe crossbrace are not installed correctly.
Do not support the vehicle on the subframe or on the subframe crossbrace (for example using a floor jack or something similar).
- Remove the bolts - arrows - and remove the subframe crossbrace.
- Remove the nuts - arrows - for the left front muffler.
- Remove the nuts - arrows - for the right front muffler.
Danger of damaging the flex joint in the front muffler.
• Do not bend the decoupling element in the front muffler more than 10°.
- Loosen the clamping sleeves - 1 - and - 2 -, push toward the rear, and remove the left and right front muffler.
- Disconnect the connectors - 1 - from the steering gear and - 2 - from the engine speed sensor (G28).
- Remove the lower cover - 1 - from the transmission - arrow -.
• Put in sixth gear; to do this, move the gearshift shaft - 1 -, push the gearshift lever - 2 - forward in direction of - arrow -.
Use the (T10172) and (T10172/5) to block the driveshaft to keep it from turning, too.
- Remove the 6 bolts - arrow - from the drive plate. Do this by continuing to rotate the clutch module over both front wheels 60° each.
- Remove the front wheels.
- Remove the left and right noise insulation - 1 - inside the wheel housing.
- Remove right and left subframe shield - 1 - (if equipped). Do this by removing the bolts - arrows - and then removing the shield toward the inside.
- Remove the nuts - arrows - and the bolt - 1 - and push the catalytic converter to the right side.
• The illustration shows the installation position with the engine removed.
• Use the (T40220) to loosen the nuts - arrow -, right catalytic converter - A - on the exhaust manifold.
• Secure the right catalytic converter loosely using a nut so it does not fall down.
- Remove the rear coolant pipe.
- Remove the air duct - arrow -.
- Disconnect the connector - 1 - on the Mass Airflow (MAF) Sensor (G70).
- Remove the vacuum hose - 3 - to the air duct pipe.
There is a risk of violating emissions regulations.
• Do not open the hose connection - 2 -!
- Lay aside the air guide hose with the crankcase ventilation hose connected - 2 - by loosening the hose clamps - 4 - and opening the clips - arrows -.
- Disconnect the vacuum line - 1 -.
- Remove the air filter housing lower section and disconnect the electrical connector - 2 - on the intake air switch-over valve (N335) on the back.
- Disconnect the hose - 3 - to the secondary air injection pump.
- Remove the coolant hose from the radiator - 2 - and from the right coolant pipe - 1 -.
- Remove the bolts - 1 - and - 2 - and the coolant hose - arrow -.
- Remove the right coolant pipe from the connection and lay it aside.
- Remove the bolts - 1 - and - 2 - and the coolant connection.
• Ignore - arrow -.
- Remove the connecting rod bolt - 3 - from the top.
• Ignore - 1 through 2 -.
- Remove the bolts - 2 through 6 - connecting the engine to transmission. They are accessible from above.
- Remove the bolts - arrows -, and remove the driveshaft heat shield - A - (if equipped).
Driveshaft Bolted on the Transmission Side:
- Remove the bolts that connect the driveshaft to the transmission by counterholding them with the (T10172) and (T10172/5).
- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.
- Secure the driveshaft to the side.
Driveshaft Mounted on the Transmission Side:
- Remove the driveshaft.
All Vehicles:
- Remove the bolt - 2 - and secure the clutch slave cylinder sideways in the engine compartment.
The clutch slave cylinder could be damaged.
• Do not press the clutch pedal after the clutch slave cylinder has been removed.
- Remove the nut - 1 -.
Danger of causing damage to the gearshift shaft inside the transmission.
• Do not pry off the transmission shift lever - 1 - using a pry bar or hit it with a hammer.
- Install the (T40160) and remove the transmission shift lever - 1 -.
The airbag spiral spring could be damaged.
• Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
• Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.
- Remove the universal joint bolt - arrow -.
- Press the universal joint off the steering gear and slide it all the way up.
- Remove the bolt - 1 - press the retaining tab off the transmission and tilt it back - arrow -.
- Remove the bolt - 1 - from the starter.
- Remove the starter from the transmission and leave it in the installation position.
- Remove the remaining bolts - 7 through 11 - that attach the engine to the transmission.
- Position the (V.A.G 1383 A) and the (T40173) under the transmission and secure it with the tensioning strap - 1 - as illustrated.
- Remove the bolts from the tunnel crossmember - arrows -.
- Lower the transmission using the (V.A.G 1383 A) first to dimension - a -.
• Dimension - a - = maximum 100 mm.
- Remove the bolts - arrows - and remove the heat shield from the right drive axle.
• The illustration shows the installation position with the transmission removed.
- Remove the bolts - arrows - and the left drive axle heat shield.
• The illustration shows the installation position with the transmission removed.
- Remove the left and right drive axles from the transmission flange shafts - arrows -.
- Remove the electrical connector - 1 - on the transmission range gear recognition switch (F208) using the (T40138).
- Remove the push rod bolt - 2 -.
• Ignore - 3 -.
- Press the transmission off the engine and lower it carefully using the (V.A.G 1383 A).
If the transmission removed is being replaced, then the following components must be changed:
• Right and left bracket - 1 - for the exhaust system.
• Tunnel crossmember with the transmission mount and transmission support. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.
• Remove the clutch module if necessary.
