Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 3.2 ltr. FSI engine Special tools and workshop equipment required

t  Ring spanner insert, 16 mm -V.A.G 1332/14-

t  Transportation lock -T40170- Procedure   Note 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. Tightening torques for installing gearbox: → Anchor –  Before fitting a replacement gearbox, always blow through the ATF cooler and ATF pipes with compressed air (not more than 10 bar) → Chapter. –  Before installing, it is important to clean any residue from threads in cylinder block using a tap. –  When fitting a replacement gearbox: attach gearbox support, gearbox mounting and tunnel cross member to new gearbox → Chapter.

–  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: –  Turn torque converter until hole is visible next to notch -arrow- in recess in bottom of gearbox housing, as shown in illustration.   Note There is only one notch at the periphery; turn the torque converter accordingly.

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

–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. –  Check whether aluminium bolts for engine/gearbox connection can be reused and mark bolts if necessary → Anchor. –  Join gearbox with engine and tighten bolts -1, 6 ... 11-. –  Remove transportation lock -T40170-.

–  Clip end seal -1- into starter aperture. l  The end seal -1- must be inserted so that it fits exactly -arrows-.   Note t  There are several different versions of this end seal (according to engine); for correct version refer to → Electronic parts catalogue t  Apply a small amount of lubricant to the end seal if the starter cannot be installed easily. –  Install starter → Electrical system; Rep. Gr.27.

–  Disengage spindles -10 - 222 A /11-.

–  Raise gearbox and tighten bolts -arrows- for tunnel cross member → Chapter. –  Slacken tensioning strap and move engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- out from underneath gearbox.   Note

The following step is necessary to ensure that the torque converter makes even and proper contact on the drive plate and does not cant. –  Press torque converter -2- slightly against drive plate -3- in direction of -arrow- using lever -1-.

–  Secure torque converter to drive plate as follows:   Note Use ring spanner insert, 16 mm -V.A.G 1332/14- to tighten bolts. –  Install first bolt -arrow- and tighten hand-tight (2 Nm).

–  Insert guide stud of adapter -T40058- as follows: l  The larger diameter -arrow 1- faces engine. l  The smaller diameter -arrow 2- faces adapter.

–  Turn crankshaft 180° in direction of engine rotation -arrow- with adapter -T40058-.

–  Tighten bolt -arrow- accessible in this crankshaft position to 60 Nm. –  Turn crankshaft 60° further each time and tighten remaining five bolts to 60 Nm.

–  Tighten remaining bolts -2 ... 5-.

The remaining installation steps are carried out in reverse sequence; note the following: –  Bolt steering column to steering box → Running gear, front-wheel and four-wheel drive; Rep. Gr.48. –  Install cross brace for subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install selector lever cable → Chapter. –  Install ATF pipes → Chapter. –  Secure left and right drive shaft to gearbox flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install heat shields for drive shaft → Fig.. –  Install propshaft → Rear final drive 0BC; Rep. Gr.39 or → Rear final drive 0BD; Rep. Gr.39. –  Install exhaust system and perform stress-free alignment → Rep. Gr.26. –  Install noise insulation panels → General body repairs, exterior; Rep. Gr.66. –  Connect battery → Electrical system; Rep. Gr.27.   Caution Overvoltage can cause irreparable damage to control units. Do not use charger for boost starting, –  Check selector lever cable and adjust if necessary → Chapter. –  Check and correct ATF level → Chapter. 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 ±15 %. Other tightening torques:

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65

Heat shield for drive shaft - tightening torque –  Tighten bolts -arrows- for drive shaft heat shield to 23 Nm.

Engine/gearbox securing bolts

Item	Bolt	Nm
1	M10x50 1)	65
2 … 6	M12x100 2)3)	30 + 90°
7	M12x125 2)3)	30 + 90°
8, 11	M10x60 2)3)	15 + 90°
9, 10	M10x95 2)3)	15 + 90°
A	Dowel sleeves for centralising
l  1) Property class 10.9. The steel bolt can be re-used any number of times. l  2) Audi A4 up to vehicle identification no. 8K-9A-066499, Audi A5 up to vehicle identification no. 8T-9A-007999: renew aluminum bolts. l  3) Audi A4 from vehicle identification no. 8K-9A-066500 onwards, Audi A5 from vehicle identification no. 8T-9A-008000 onwards: aluminium bolts can be used twice only → Anchor.

t  Audi A4 from vehicle identification no. 8K-9A-066500 onwards, Audi A5 from vehicle identification no. 8T-9A-008000 onwards: aluminium bolts -2 ... 11- 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.