Audi Workshop Service and Repair Manuals

Installing gearbox on vehicles with 4.2 ltr. MPI engine   Note t  Re-attach all cable ties at the same locations when re-installing. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Re-attach heat shield sleeves at the same locations when re-installing. t  Renew self-locking nuts.

–  Before installing gearbox, you must ensure that the torque converter is properly fitted in the gearbox. l  If the torque converter is correctly installed, the depth between the contact surfaces at the tapped holes on the torque converter and the contact surface of the torque converter bellhousing is at least 19 mm.   Caution If the torque converter is not fitted correctly, the torque converter drive lugs or the ATF pump will be irreparably damaged when the gearbox is joined to the engine.

–  Before installing gearbox, check for correct positioning of dowel sleeves -A- at cylinder block. Install new dowel sleeves if necessary. –  If an intermediate plate was installed between engine and gearbox, reinstall plate in same position. –  When pushing the engine and gearbox together, ensure that no wiring or pipes etc. can become trapped.   Caution Before and while you are tightening the bolts on the engine/gearbox flange keep checking that the torque converter can still be rotated behind the drive plate. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened. –  Bolt gearbox onto engine → Anchor. –  Use new ribbed bolts to secure the torque converter to the drive plate. Use only the correct bolts (same as original equipment) → Electronic parts catalogue.

–  Insert guide pin of adapter -T40058- so that the large diameter -arrow 1- faces engine. The smaller diameter -arrow 2- faces adapter. –  Counter-hold crankshaft using adapter -T40058- to secure torque converter bolts.

–  Screw the 3 torque converter bolts through the opening for the starter (finger-tight). Turn the crankshaft 1/3 of a turn to access one bolt after another. –  Then tighten torque converter bolts to torque (turning the crankshaft 1/3 turn each time).

–  Insert engine speed sender -G28--item A- into bell housing (top left) and tighten bolt -1-. –  Install heat shield -B- and tighten bolt -2- (gearbox/engine bolt connection → Anchor)

–  Insert ATF cooling pipes -A- and -B- into gearbox as far as possible and tighten bolt -2-.

–  Press selector lever cable -1- onto selector shaft lever -3-. –  Install starter → Electrical system; Rep. Gr.27. –  Install gearbox support with gearbox mounting → Chapter. –  Install front exhaust pipes → Rep. Gr.26.

If measurement performed with locating pin -3393- during removal showed that holes -1- and -2- were aligned: –  Install the subframe, observing tightening sequence → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. If measurement performed with locating pin -3393- during removal showed that holes -1- and -2- were NOT aligned: –  Only tighten bolts for subframe to torque setting, do not yet turn further (wait until wheel alignment has been carried out).   WARNING The vehicle must not be driven in this condition. –  Clean ATF pipes and ATF cooler → Chapter. –  Secure ATF pipes to gearbox and engine → Chapter.

–  Bolt on the support bracket for selector lever cable -arrows-. –  Secure propshaft to gearbox → Rear final drive 01R; Rep. Gr.39.

–  Secure heat shield -A- for propshaft -arrows-. –  Install exhaust system so it is free of stress → Rep. Gr.26. –  Bolt drive shafts to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Install heat shields -arrow- for drive shafts (left and right). –  Adjust selector lever cable → Chapter. –  Check oil level in front final drive → Chapter. –  Check oil level in transfer box → Chapter. –  Follow steps required after connecting battery → Electrical system; Rep. Gr.27. –  Check ATF level → Chapter. –  If necessary, carry out wheel alignment → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.44.   WARNING After wheel alignment tighten subframe bolts to their final torque setting. 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 gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased.

Drive plate to torque converter	Nm
Ribbed bolts, M10x1x21.5 (3x) → Note → Note
4.2 ltr. MPI engine	85

1)  Renew bolts. 2)  Use only genuine bolts → Electronic parts catalogue.

Illustration of gearbox flange A: dowel sleeves for centralising Securing engine to gearbox:

Item	Bolt	Nm
1	M12x80	65 → Note
8	M10x60	45
9	M10x60	45
10	M10x60	45

3)  Also secures starter. Securing gearbox to engine:

Item	Bolt	Nm
2	M12x105	65
3	M12x110	65
4	M12x105	65
5	M12x105	65
6	M12x130	65 → Note
7	M12x170	65

4)  Also secures a heat shield.

Component	Nm
Engine speed sender -G28- to gearbox	10
Bracket for ATF pipes to gearbox	21
Bracket for exhaust pipe lug.	23
Heat shields above drive shafts to gearbox	23
Heat shield for propshaft to gearbox cover	25
Bracket for noise insulation to subframe	10
Support bracket to gearbox	10