changing A4LD with exhaust intact (It can be done)

[1991XLT]

I had to replace my Tranny in my 94 X over the last weekend.. wow.. what a job it became. I had 2nd gear go out on my old tranny so found a tranny from a 91 that was rebuilt not long before it was rolled. the guy sold it to me for 150.00. I thought that was a super great deal for a good working A4LD. I also put a new seal in the transfercase output for rear driveshaft. anyways.. I have a question for everyone who has changed out a tranny on one of 1st gens. Did you remove the crossover pipe? I would of loved too but the bolts were very rusty and I figured as soon as I would attempt to remove the exhaust things would start crumbling and I would end up with a leaky junk exhaust of which I don't wanna replace right now.. soooo I was able to "squeeze" the tranny bellhousing over the crossover pipe and under the floor by letting the engine down all the way where the crossover pipe rested on the crossmember along with some messin around with the floorjack the tranny was sitting on I was able to get it out and the replacement tranny in.. It was very close to the o2 sensors aswell but it does clear them.. the only biggest problem I found was getting at the bellhousing bolts a few of them were not the easiest to get too. oh and one of the tranny lines got bent a little bit so with exhaust on that was sorta fun trying to get that bent back and lined up with the tranny. It took me over an hour to just put both of them lines on.. LOL also before I put the new tranny in I took air pressure and blew all the old fluid out of my tranny cooler.. Mine must have the towing package as it does have a tranny cooler in front of the radiator. also another little tip i always do.. to index all your driveshafts I use spray paint to paint a little bit on just one side to mark where your shaft needs to be when you reinstall it.. I am not sure if there is an extensive writeup on installing a A4LD but if not and people are interested I could maybe see what I can come up with.

 

[410Fortune]

the exhaust takes a few minutes to drop and saves you ALOT of hassle when doing a trans change.
The first time, when the factory bolts are frozen, etc it can be a PITA, but it will come apart with the right tools and you can use better fasteners/hardware to put it abck together.

It is just a Y pipe to cat,2 02 sensors, 7 bolts?
People with a body lift can do it even easier, I have done it before with the exhaust in place, but I would not do it that way again.

 

[Nuggethead 420]

If The exhaust has never been off it may take more than a few minuets to get it off and I still have not figured out how to get the 2 of 3 broken studs out of the cat-converter. have clamps holding them together at the stud points.
I have done it both ways exhaust out and in. 410Fortune is right lots easier with it out more room to work and to move the tranny into position for re assembly.

Good luck

 

[410Fortune]

go to an exhaust shop and have them press in new studs on your cat flange.

 

[Nuggethead 420]

So far they want $60-80 to do it and that is if it is all ready out.
What a racket!!!

 

[410Fortune]

you need a new shop.
$50 is actually prett fiar for the whole thing, IMO, but then I have been using my exhaust dude for a while now, hes a friend.

If you can pound the studs out yourself you can replace them with bolts

You could also cut the piece off you need from a junk yard truck (bring exhaust home, then cut, etc) and have them weld in the part from y pipe back to cat, shouldnt be more then $50 either.

 

[Nuggethead 420]

We have a hydraulic press hear and I can buy some studs to put in, it just sounds more along what I want......Free!!
Have to put in another a4ld soon so I want it done.