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AdamS4

And So it Begins...... Engine Pull Number 2

As some may recall, my gearbox has recently developed a nasty clunking noise. It doesn't even have to be in a gear for it to clunk when the car is moving. While it was at MRC, they were kind enough to have a quick look at the centre diff and we found metal shards that looked like teeth off a gear but the centre diff looked intact. There were a few scratches round the outside of the diff and the oil was all metalically aswell. Whats broken ??... who knows.... thats for me to find out. I've found a 2nd hand gearbox so hopefully i can just do a straight swap.

Today i had a couple of hours so got started on getting it up in the air and removing bits and pieces. I'll let the pictures do the talking:








AliGod78

Re: And So it Begins...... Engine Pull Number 2

AdamS4 wrote:
As some may recall, my gearbox has recently developed a nasty clunking noise. It doesn't even have to be in a gear for it to clunk when the car is moving. While it was at MRC, they were kind enough to have a quick look at the centre diff and we found metal shards that looked like teeth off a gear but the centre diff looked intact. There were a few scratches round the outside of the diff and the oil was all metalically aswell. Whats broken ??... who knows.... thats for me to find out. I've found a 2nd hand gearbox so hopefully i can just do a straight swap.

Today i had a couple of hours so got started on getting it up in the air and removing bits and pieces. I'll let the pictures do the talking:



Mission!? I wouldn't know where to start - little more complicated than an old 950cc OHV Fiesta! Good luck mate.
jimbo

why are you taking the engine out adam, you can get the gearbox off by taking the dp,s off, back subframe bolts, loosen the front ones, undoo front drive shafts and diff then gear linkage and slave on top of the box, undoo the the gearbox bolts and hey presto, have a strong mate ready.  
calibra_se8

Good luck!
Trig

Oooooooo, looks familiar!!!

What IS the best way to change a box/clutch????

Got to do this in a few weeks so.....................

Engine pull,engine and box pull or just the box out???????????

Can't face the motor out again.......
AdamS4

Jimbo, I haven't got the clearance under the car to do it that way. I'm happy enough to pull the engine and box together. I not exact working on the best surface I'm planning on extending my garage but for now, my driveway will have to do.

I might do some other bits to it while its out anyway.
bluebrakes

i would have thought lining the clutch up would be a pain the arse without a ramp anyway.
Byzan a4

eeekkk rolling the engine crane will be easy on that surface. Very good luck mate, kudos to you.
AdamS4

I'll be putting down sheets of ply when it comes to that
mikeyquattro

Fair play to you Adam. Tops marks for determination
TinTin1201

Biggggggg Balls for this one Good luck!
BigD's-S4

You have been busy....Good progress mate, you obviously know your stuff  
MarkB

Moved to Projects and Builds as I know that's where you'd like it.

Lets hope the weather stays good for you.
pjbRs

wow fair play to you to do this youself, i would have had bloodied knuckles and a box of broken bits by that stage. Hope you find the problem, very helpful pictures too.
jimbo

youve been chosen. .....                                          
Matt_D

Gutted for you mate

i have an official audi gearbox/diff build manual if you want to borrow it ?
GHH

good luck dude, fingers crossed for the weather.
AdamS4

Matt_D, i might take you up on that offer, cheers.

Today, spent a couple of hours getting it off the ramps and onto axle stand ready for front driveshaft disconnection. Prop shaft and exhaust is disconnected and so is the gear selectors:





All thats left before the actual pull is:

Disconnect front drive shafts
Disconnect loom from ECU and all earthing points
Disconnect fuel lines
Disconnect AC lines (No gas in there anyway)
Disconnect power steering line from reservoir
Disconnect coolent lines at rear of engine
Disconnect clutch slave cylinder
Undo mounting nuts
supersi

Max kudos mate ..
AdamS4

Again, another couple of hours work today. Front drive shafts disconnected, loom disconnected, fuel lines disconnected, power steering disconnected etc etc. Engine/box is pretty much ready to come out now. All thats left is:

Disconnect coolent lines at rear of engine
Disconnect clutch slave cylinder
Undo mounting nuts
Remove engine/box

Some pics as aways:








BigD's-S4

You have been busy.....Keep it up mate, good work  
Matt_D

email sent ref build manual
ScottR

Excellent progress, keep up with the pics!
calibra_se8

It feels never ending doesn't it

You get loads of stuff undone then realise there's more
AdamS4

Got the engine and gearbox out today... all was going well untill i forgot to disconnect the clutch slave cylinder.... well I started to undo it from the gearbox but got side tracked and as we pulled the engine out..... SNAP... and the hose brakes off the clutch slave cylinder

DAMN DAMN DAMN !!!

Pictures soon when i start to take apart the gearbox.
pjbRs

I would never remember how it all goes back ! i take it you've done this before?

Keep the pics coming and respect to you fella.  
AdamS4

I've done it once but its pretty simple really. It looks like alot of stuff to remove/undo and it is alot but its stuff your'll easier remember and things just fit.... if thats makes sense.
stefan

Nice, this is such a good example for me when I'm going to replace my turbos in the near future (and downpipes with it).
It's even the right color, so it's actually like I'm looking at my own car!

Two questions at the moment, hope you can answer them
Did you just leave the front axles in the wheel hubs, hanging loose near the transmission housing, or did you remove them altogether?
What use-once items are in there, except for the clamps in the intake routing?
jimbo



dont forget to disconnect the headlight level sensor on the 10mm nut, you can see here its strained already. when you lower the subframe it will either bend the bracket or something will snap.
AdamS4

Hi stefan,

I left the front suspension, drive shafts etc as you see them.

I did have to remove the downpipes once the engine was pull forward enough as they catch on the drive shafts and you can't move them over the gearbox mounting arms when the DP's are in place.

Nothing removed is a use once item, just make sure you use lock tight/thread locker on the key bolts i.e drive shaft, prop shaft bolts, engine/gearbox mounting bolts etc.

Jimbo, i'm not removing the subframe and i disconnected that after that photo was taken.
audimad100

Top Man Adam you will be able to do this in your sleep soon  when i come to do my KO4 conversion i dont supose you fancy a few days in sunny Cornwall
AdamS4

LOL... your ~300 miles from me... In the deep of cornwall !!

I'll happliy guide you via AudiSRS.com
audimad100

        i would have brought you a lovely cornish ice cream, and would have even stretched to a flake in it. mmmmmmmmmmmmmmmmm
jimbo

It helps if you remove the subframe bolts and let it drop a few inches.
AdamS4

Right, engine and gearbox was removed the other day. God i forgot how much of a pain it is to split the engine and gearbox !!

Today i spent an hour or so on the gearbox. Started removing bits and pieces, front and centre diffs etc etc.

From removing the centre diff, its clear that some teeth have been through it... found 2 more in addition to the 3 or 4 we found while it was at MRC !!. Both the centre diff and housing had taken a beating.

The magnet are covered in metal flakes.

Anyone know what the next step is ? How do i split the gearbox ???





















s4marsh

good work adam..Jhmotorsport do a video of a gearbox rebuild Has anyone on here got that maybe?
http://jhmotorsports.com/shop/cat...=d9e84a4c37b5308ab74904d666538d49

there is a trailer of it on that page too
AdamS4

I've seen the gear thats broken... its the last gear right before the centre diff.

Anyone know what gear that is ?
AdamS4




AdamS4

With the help of viberbl, i've serparated the centre diff housing from the gear housing and finially discovered the gear thats missing the teeth...





Laaf

Oh dear god doing work on gearboxes is awful, the oil really smells like crap. But I see I'm lucky as I yet has had to split the gearbox for the snowmobile, not my Audi But a couple years ago I split a old Volvo box, and that was a pain.
AdamS4

2nd hand gearbox has arrived....

MikeCS4

nice one Adam, any tips for splitting the engine & geabox ?????
pjbRs

Again big respect for stripping it all down yourself, that gear has definately taken a beating!
glad you got a donnor box, now the rebuild starts?
BigD's-S4

Yeah hat off to you mate...Your really getting stuck into it, and doing a top job, even finding the time to take the pics and keeping us lot up to date
AdamS4

Thanks guys

Thats not a donor box... its now my main box. Its going straight back in the car as soon as i''ve got some time and changed the gearbox oil.

Mike, make sure the engine is on flat level ground and then wiggle the gearbox off. Becareful as the box is bloody heavy.
AdamS4

Update

Got the new 2nd hand gearbox mated to the engine the other day... man that was hard work doing it by myself !!!

Today, changed the gearbox oil and actually the oil in it wasn't too bad, still clear ish.

Finally got the engine and box back in the car and was doing up the engine mounts and i must of cross threaded the bolt as it snapped So i'm on the hunt for a engine mount (hence my thread in the Wanted section).

Hardest bits has been done now its a matter of bolting it all back together.... Just need a couple of dry days !!
pjbRs

Just hide the big box of left over bits.

or would that just be me?
calibra_se8

Keep going mate, just think of the drive when you're finished
AdamS4

MY GOD, now i wish i'd taken the gear selector box out with the engine/box or at least refitted while the gearbox was out !! It was a right pain in the ass trying to get the selector forks back into the rubber gromet and then back into the selector box !!

Word of advice, either take the gear stick selector box out with the gearbox/engine or remove it and refit while its all out.

So i guess you know what i did this morning... yup, refitted the gear selectors to the inside of the car. Most gears work but won't know untill the engines running and clutch is working. Fine adjustment is whats needed.

Still searching for an engine mount, can't continue without it as i don't want to start bolting things back up just incase i need to lift/remove the engine again.
AdamS4

Thanks to andream88, i've fitted a pair of RS4 engine mounts and the rebuild has begun again !!!

Today, i fitted the engine mounts, bolted up the drive shafts, put the suspension back, got it off the car stands and all 4 wheels are now back on !!! Its actually starting to look like a car again.

Car is now sitting on a pair of ramps so i can connect up the prop shaft and downpipes to the rest of the exhaust system.

Then i need to connect everything back up in the engine bay !!

I also took of the viscous fan. Lets see what happens.
AdamS4

WOOOOOOHOOOOOO

Car is up and running.

Just need to bleed the clutch and refit the front bumper and fingers crossed.... all is well




pjbRs

Well done mate, i hope its all running fine now. Just before the snow comes next week too.
lynchy

Good to hear Adam
MathiasS

Nice work !
MikeCS4

Nice one Adam, i'm hoping to get mine sorted and back on the road this week as well
philws4

Excellent work Adam, well done
andream88

well done Adam
jimbo

carbon y pipe?
bluebrakes

jimbo wrote:
carbon y pipe?


carbon wrap?  
MikeCS4

jimbo wrote:
carbon y pipe?


good spot, or is it carbon wrap
audimad100

great thread Adam, top work matey good to see her all back together again    
AdamS4

Yes, its 3M Carbon wrap

Thanks guys Can't wait to get out in her again.

Then once confirmed all is good, its back up to MRC to have the mapping finished.

Its only been 3 months !!!  
AdamS4

Finally the car is fully operational again !

Apart from 1 new issue... I've got a hole in my rad Rad weld has fixed it for now but need to find a rad
okkim

AdamS4 wrote:
MY GOD, now i wish i'd taken the gear selector box out with the engine/box or at least refitted while the gearbox was out !! It was a right pain in the ass trying to get the selector forks back into the rubber gromet and then back into the selector box !!

Word of advice, either take the gear stick selector box out with the gearbox/engine or remove it and refit while its all out.


It is much easier to just unbolt the gear selector rods from the selector box, and remove those with the rubber grommet.
MikeCS4

Nice one Adam, let me know if you fancy a test drive over this way
BigD's-S4

AdamS4 wrote:
Finally the car is fully operational again !

Apart from 1 new issue... I've got a hole in my rad Rad weld has fixed it for now but need to find a rad


Excellent news mate, i bet your well pleased....The rad is minor compared to what you've done over the past few months. Good work, now you can enjoy, just in time for the snow
jimbo

good work adam. it gets easier the second and third time.  
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