The D2 Forums

Yes, a lot of parts are NLA if you go to Audi and ask for something, especially unprepared without the part number in hand but...
if you know the right people, a lot of parts are still available or we know of parts from other VAG products (and even BMW) that are like for like replacements, it just takes a little bit more effort. We even have a dedicated section where you can request or ask for part numbers.

Dean (Spanker) is very good at sourcing parts and we even have a dedicated forum section for him, where he doesn't need to hide his services like on a8parts forum who sell tradition parts with 2-3x markup but can't make the forums safe and reliable for its loyal members.

Hi again all
Whilst my car is pretty much a drive ornament at the moment my brain keeps turning over looking for options. Here is one I would like opinions on please.

Is it possible to remove the engine whilst leaving the gearbox in the car?

My initial starting point on this project, should I decide to proceed, was to drop the subframe complete with engine and gearbox. This is going to be a challenge on the drive but I think it's the easiest option mechanically. By that I mean things are easier to access. It does though present a manual handling issue.

So, my brain says why not remove the engine only. If I believe (which I do) that this is an "A" clutch issue only, I can access the front of the gearbox whilst sitting in the engine bay. If I pull the drive shafts out through the wheel arches, remove the front diff and the drive shaft tube, I should be able to remove the gearbox oil pump. The A Drum will then be there for the taking. I could then replace all the "O" rings and thrust bearings.

This is clearly not a full rebuild but a repair. I would also drop the gearbox oil pan before starting any work as any sign of shrapnel in there would make this procedure pointless.

Problems I forsee are.
1 Removing the exhaust down pipes. Is this doable with the engine in the car?
2 Access to the torque converter bolts will mean removing the starter motor. Is this possible with the engine in the car?
3 The bell housing bolts at the top may be difficult to access but I'm thinking of removing the intake Manifold again so hopefully that will give me a chance.

What do you think, doable?

Not doable I'm afraid, mostly because the gearbox needs to be vertical, sitting on its tailshaft flange, to get it to go back together. Its practically impossible to get the gubbins back inside while gravity is messing with the clutch packs. When I did mine I took it apart on the bench, but to get it back together I had to put the casing on the floor and strap it to one of the legs of the bench so I could drop the A drum back in. ZF had a special tool for rotating the casing to allow it to be assembled.

Its also far more difficult to get the engine out on its own than to just drop it as one chunk. Downpipes aren't too bad - soak them in penetrant for a bit and you can do them from the wheel wells. Bellhousing bolts I've not tried on an auto, but on my manual I just do it with a long extension (5 feet) and a wobbly joint from the back of the gearbox. TC bolts in the car are pretty horrid - the engine mount has to come off to get the starter out

Its worth keeping an eye on FB Marketplace, Gumtree etc for a secondhand pallet truck. This makes dealing with the whole assembly far more practical. It fits nicely on to a lengthways Euro pallet and a few blocks and then you can lift the engine and box off the subframe with an engine crane. Support the gearbox and take the engine off the box, not the other way round. The engine's centre of gravity and inertia are obvious and predictable. The gearbox, not so much.

Plenty of people do take the gearbox out and leave the engine - I've seen it done like that on axle stands, but I wouldn't fancy it myself.

Thanks for that detailed reply MJ, very much appreciated. I'll go back to planning dropping the engine gearbox and subframe complete.

I take your point also about aligning the clutch plates with the box in the horizontal position. I bought a 5hp24 from a BMW to practice stripping and rebuilding with good success. I automatically stood it on it's end in my workshop and so never even considered how much more difficult it would be horizontally. Of course they will drop under gravity. Dumb ass!

Well, its not that obvious. The 5HP19 for example has to be assembled horizontally as its clutch drums will come apart if you do it vertically. You'd assume it would be the same as the 24, but its quite different inside.