0A3A Transmission

Transmission, 8-Cylinder MPI, Audi S4, Removing

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Shackle (10-222 A /12)

• Lifting Tackle (2024 A)

• Hose Clamps up to 25 mm Diameter. (3094)

• Transmission Support (3282)

• Adjustment Plate (3282/38)

• Testing Mandrel (3393)

• Engine/transmission Jack (V.A.G 1383 A)

• Fender Liners (T40045)

• Drill bit dia. 10.2 mm

• Bolts M10x20 (qty. 2)

• Grease For Clutch Disc Shaft Splines (G 000 100 )

• Copper Grease (Z 381 351 TE)

Removing

• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.

• Heat shield sleeves removed during removal should be placed in the same location when installing.

CAUTION!
Observe procedures for disconnecting battery.

- With the ignition switched off, disconnect battery Ground (GND) cable - arrow -.





- Remove rear engine cover - arrows -.





- Remove front engine cover - arrows -.





- Remove left cover - 1 - in engine compartment.





- Clamp off coolant hose - 1 - with Hose Clamps up to 25 mm Diameter. (3094) and remove from coolant reservoir.





- Remove coolant reservoir - 2 - - arrows -.

- Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch (F66) at bottom of reservoir and lay aside coolant reservoir with coolant hose - 3 - connected.

- If necessary, seal connector with proper plugs.

- Remove electrical harness connectors - 1 through 4 - from bracket at left of bulkhead.





- Disconnect electrical connectors - 1 -, - 3 - and - 4 -.

- Remove bracket on bulkhead.

- Remove heat shield sleeve on wiring harness and expose wiring harness.

- Expose oxygen sensor wiring below.

- Remove right cover - 1 - in engine compartment.





- Remove air guide hose - arrows -.





- Remove connectors - 1 through 4 - from bracket at right of bulkhead.





- Disconnect electrical connectors - 2 - and - 4 -.

- Expose oxygen sensor wiring below.

- Secure Shackle (10-222 A /12) at right rear engine lifting eye.





• Disregard - 1 -.

- Remove sealing rubber on bolted fender flanges.

- To prevent damage to fender edges when using Engine Support Bridge (10-222 A), insert Fender Insert Pads (T40045) on both sides between bolted fender flange and web plate lying beneath.





- Place Engine Support Bridge (10-222 A) on bolted fender flange.





- Remove eyelet for Engine Sling (2024 A).





- Re-insert bolts - 1 - in middle engine sling hole and secure with a spring clip.

- Insert Engine Sling (2024 A) bolts at Engine Support Bridge (10-222 A) spindle.

- Engage Engine Sling (2024 A) in front lifting eye and in Shackle (10-222 A /12) on rear of engine.

CAUTION!
Mounting hooks and connecting pins on engine sling must be secured with plug connectors - arrows -.

- Take up weight of engine on support bar spindle a little, but do not lift.

- Remove both front wheels.

- Loosen quick-release connectors - 1 -, remove screws - 2 - and remove noise insulation.





- Remove noise insulation bracket - arrows -.





- Remove wiring harness bracket at right of engine bracket - arrows -.





- Remove nuts - 1 - at bottom on left and right engine mounts.





- If equipped, unclip Level Control System Sensor operating rod at lower control arm - arrow -.





- Before loosening subframe, you must check whether Testing Mandrel (3393) can slide completely into holes - 1 - and - 2 - in subframe - arrow -.





CAUTION!
If this is not the case, vehicle alignment must be carried out after installing subframe.

- First remove front bolts - 2 - and - 3 - at left and right subframe. Then remove bolts - 1 -.





- Lower front subframe.

- Remove lower engine/transmission bolts - arrows -.





- Initially re-tighten subframe. Initial tightening specification:





1. 110 Nm

2. 75 Nm

3. 75 Nm

CAUTION!
Bolts are replaced after installing transmission and tightened to final tightening specification.

• Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.





- Disconnect exhaust system at double clamps - arrows -.

- Place plunger of Engine/Transmission Jack (V.A.G 1383 A) with a block of wood inserted between - 1 - on lower crossmember.





- Support lower crossmember using Engine/Transmission Jack (V.A.G 1383 A).

- First remove bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.

- Slowly lower crossmember using Engine/Transmission Jack (V.A.G 1383 A).





• Transmission must only be lowered enough so that the distance between the rear crossmember and the body (dimension - x -) is a maximum of 60 mm. Otherwise, driveshaft joint and flex joint in front exhaust pipe can be damaged. If necessary, re-tighten Engine Support Bridge (10-222 A) at spindle so that dimension - x - is not exceeded.

- Remove head shields - arrow - for left and right drive axles.





- Remove drive axles from transmission flange.

• Make sure drive axle protective coating is not damaged.

- Remove selector rod connecting rod - 2 -.





- Remove push rod - 1 - by unbolting socket head hex bolt.

- Expose oxygen sensor wiring at places on transmission marked with - arrows -.





• Shown in illustration with engine/transmission assembly removed.

- Remove bolt - arrow - at left exhaust pipe strap.





- Remove left front exhaust pipe/manifold nuts - 1 to 3 -.





• Shown in illustration with engine removed.

- Remove front exhaust pipe from left exhaust manifold.

- Remove front exhaust pipe.

- Remove bolt - arrow - at right exhaust pipe strap.





- Remove right front exhaust pipe/manifold nuts - 1 to 3 -.





• Shown in illustration with engine removed.

- Remove front exhaust pipe.

- Remove driveshaft heat shield - arrows -.





- Remove bolts - arrows - at transmission/driveshaft flange.





- Push driveshaft toward rear final drive. CV joints can be moved axially.

- Allow driveshaft to rest on rear part of exhaust system.

- Remove both nuts - arrows - and remove tunnel crossmember.





- Remove nut - 1 - and pull transmission shift lever - 2 - from selector shaft of transmission.





- Disconnect connector - arrow - on the Back-Up Light Switch (F4) on the right side of the transmission and free up the wire.





- Remove starter - 1 - - arrows - and remove from transmission case.





- Remove remaining engine/transmission bolts. 2 bolts remain installed hand-tight.

- Remove left front exhaust pipe strap at transmission - arrows -.





- Make a hole 10.2 mm dia. - arrow - in Transmission Support (3282) support piece.





- Position Transmission Support (3282) for removing manual transmission 0A3 with Adjustment Plate ( 3282/38) and place on Engine/Transmission Jack ( V.A.G 1383 A).





• Support piece - arrows - is represented figuratively on adjusting plate, arrow points in direction of travel.

• Adjusting plate only fits in one position.

- Align adjustment plate parallel to transmission.





- Secure support pieces at left of transmission as shown in illustration. Tighten M10x20 bolt - right arrow - to 20 Nm.

- Secure support pieces at right of transmission as shown in illustration. Tighten M10x20 bolt - left arrow - to 20 Nm.





- Remove last 2 engine/transmission bolts.

- Press transmission out of alignment sleeves and carefully lower with Engine/Transmission Jack (V.A.G 1383 A) until clutch slave cylinder is accessible.

• When lowering the transmission, make sure the hydraulic line to the clutch slave cylinder is not damaged.

- Remove clutch slave cylinder - arrow - and tie up with wire, do not open line system.





CAUTION!
Do not press clutch pedal after clutch slave cylinder has been removed. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.

- Completely lower transmission.

• Pay attention to drive axle clearance when lowering.

- If the transmission removed is replaced, the transmission supports of the old one must be fitted to the new one - arrows -.