Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 3.0 ltr. TFSI engine Special tools and workshop equipment required

t  Assembly aid -T40169-

t  Transportation lock -T40170-

t  Ring spanner insert, 16 mm -V.A.G 1332/14- Procedure   Note t  Renew bolts which are tightened by turning through a specified angle. The aluminium bolts securing the engine to the gearbox can be used twice only. t  Renew bolts which are tightened by turning through a specified angle. t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Re-attach all cable ties at the same locations when re-installing.

t  Check input shaft of removed gearbox for scoring around bearing in drive plate -arrow-. Renew needle bearing in drive plate if necessary → Rep. gr.13. Tightening torques for installing gearbox: → Anchor

–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. l  Check whether aluminium bolts -2 … 11- can be reused for engine/gearbox connection and mark bolts if necessary → Anchor.

–  Install clutch module if previously removed → Servicing 6-speed manual gearbox 0B4, four-wheel drive; Rep. gr.30.

–  Position gearbox on gearbox support -T40173- and secure with tensioning strap -1-, as shown in illustration.

–  The following preparations must be made before joining the engine and gearbox: –  Insert assembly aid -T40169- into gearbox housing and clutch module from below, as shown in illustration. l  The assembly aid -T40169- must engage in the semi-circular recess -1- and in the inspection hole -2-.   Note There is only one inspection hole at the periphery; turn the clutch module accordingly. –  Insert pin on handle of assembly aid -T40169- into hole in gearbox housing.

–  Insert transportation lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-.

–  Raise gearbox just far enough to be able to insert clutch slave cylinder. –  Tighten bolt -2-. Tightening torque → Item   Note

The next step is only required if a drive plate with locating pins -2- is installed. –  In addition, align drive plate with clutch module so that locating pins -2- (if provided) on drive plate can engage in large holes -1- on clutch module.   Caution An incorrectly installed clutch causes functional problems. If the locating pins on the drive plate -2- are not located in the holes on the clutch module -1-, this will lead to considerable functional problems of the clutch.

–  Join gearbox with engine and tighten bolts -3 ... 11-. Tightening torques → Anchor

–  Raise gearbox using engine and gearbox jack -V.A.G 1383 A- initially only until dimension -a- is reached between tunnel cross member and body. l  Dimension -a- = 100 mm (maximum)

–  Fit starter and tighten bolts -1- and -4-. Tightening torque → Anchor   Note -Items 2 ... 3- can be disregarded. –  Tighten catalytic converter (right-side) → Rep. gr.26.

–  Secure push rod -1- → Item. –  Secure connecting rod -3-. Tightening torque → Item –  Plug in connector -2- at gear detector switch -F208-. –  Plug in connector at engine speed sender -G28-.

–  Install gearbox selector lever -2- as follows: l  Gearbox selector lever -2- can only be fitted onto selector shaft -1- in one position (gap in splines -arrow-). –  Secure gearbox selector lever -2-. Tightening torque → Item

–  Secure drive shafts (left and right) to flange shafts on gearbox → Rep. gr.40. –  Tighten bolts -arrows- for drive shaft heat shield to 23 Nm.

–  Release spindles of support bracket -10 - 222 A-. –  Raise gearbox further and tighten bolts -arrows- for tunnel cross member. Tightening torques → Chapter –  Detach engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- from gearbox. –  Remove support bracket -10 - 222 A-.

–  Install propshaft or attach to gearbox → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39. –  Assemble exhaust system and align so it is free of stress → Rep. gr.26.

Tightening sequence – clutch module to drive plate –  Remove assembly aid -T40169- and transportation lock -T40170-. –  Engage 6th gear by pulling out selector shaft -1- and shifting gearbox selector lever -2- forwards in direction of -arrow-.

–  Fit both front wheels. Hold propshaft with counterhold tool -T10172- and adapters -T10172/5- to prevent it from turning.   Note

The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant. –  Turn both front wheels together in one direction until the clutch module has turned through one complete revolution (360°). l  The inspection hole -arrow- should be visible again in the recess on the gearbox housing.

Secure clutch module to drive plate as follows: l  Use new bolts. l  Tightening torque → Item l  Tighten bolts using ring spanner insert, 16 mm -V.A.G 1332/14-. –  Install first bolt -arrow- and tighten hand-tight (2 Nm). –  Turn both front wheels so that clutch module/drive plate turns 180° further. –  Now install second bolt and tighten to specified torque → Item. –  Now install remaining bolts securing clutch module to drive plate all round, and tighten immediately to specified torque (also tighten the first bolt installed) → Item.

–  Secure universal joint -arrow- to steering box → Rep. gr.48. –  Attach hydraulic lines for power steering → Rep. gr.48. –  Install subframe cross brace → Rep. gr.40. –  Fill up with hydraulic fluid for power steering → Rep. gr.48. –  Check gear oil level in gearbox → Chapter. –  Tighten wheel bolts on both front wheels to specified torque → Rep. gr.44. –  Observe correct procedure after connecting battery → Rep. gr.27.   Caution Overvoltage can cause irreparable damage to control units. Do not use charger for boost starting. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques is ± 15 %.

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:

Engine/gearbox attachment (3.0 ltr. TFSI engine)

Item	Bolt	Nm
1 1)	M10 x 50 2)	65
2 1)	M12 x 100 3)4)	30 + 90°
3 … 6	M12 x 100 3)4)	30 + 90°
7	M12 x 125 3)4)	30 + 90°
8, 11	M10 x 60 3)4)	15 + 90°
9, 10	M10 x 95 3)4)	15 + 90°
A	Dowel sleeves for centralising
l  1) Also secures starter. l  2) Property class 10.9; the steel bolt can be re-used any number of times. l  3) Audi A4 vehicles up to vehicle identification no. 8K-9-066499, Audi A5 vehicles up to vehicle identification no. 8T-9-007999: renew aluminum bolts. l  4) Audi A4 vehicles from vehicle identification no. 8K-9-066500 onwards, Audi A5 vehicles from vehicle identification no. 8T-9-008000: aluminium bolts can be used twice only. l  Checking whether aluminium bolts -2 … 11- can be reused → Anchor.

Checking whether aluminium bolts -2 … 11- can be reused t  Audi A4 vehicles from vehicle identification no. 8K-9-066500 onwards, Audi A5 vehicles from vehicle identification no. 8T-9-008000 onwards: the aluminium bolts (see illustration) can be used twice only. After they have been used once, an „X“-arrow- must therefore be chiselled onto the bolts. t  To prevent damage to the bolts, they must not be clamped in a vice when marking them. Clamp a 14 mm socket with 1/2" drive in the vice instead, and insert the bolt into the socket, as shown in illustration. t  Bolts marked with an „X“ must not be used again. t  Audi A4 vehicles up to vehicle identification number 8K-9-066499: always renew aluminium bolts. t  Audi A5 vehicles up to vehicle identification number 8T-9-007999: always renew aluminium bolts. t  The steel bolt can be re-used any number of times.