Audi Workshop Service and Repair Manuals

Installing gearbox Special tools and workshop equipment required

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

t  Assembly aid -T40169-

t  Transportation lock -T40170- Tightening torques for installing gearbox: → Anchor 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  Hose connections and air pipes and hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  To ensure that the air hoses can be connected securely, you must spray the screw threads on used screw-type clips with rust remover prior to installation. t  Re-attach all cable ties at the same locations when re-installing.

There are two different types of ATF filter, depending on the engine version and date of manufacture. In-line ATF filter -5- and in-line ATF filter -10-. t  The exchangeable ATF filter -10- must be renewed every time the ATF is changed or the gearbox is repaired. t  The in-line ATF filter -5- must be renewed when the gearbox is renewed or if the ATF is very dirty. Removing and installing → Chapter.   Caution Risk of damage to components. When a gearbox with in-line ATF filter -5- is replaced with a gearbox with exchangeable ATF filter -10- t  the ATF supply line and ATF return line must be renewed → Chapter. The ATF lines are NOT interchangeable. Leakage and damage to the ATF lines will occur if the ATF lines are not renewed. t  The exchangeable ATF filter -10- must be renewed every time the ATF is changed in the future. Please make appropriate entries in the vehicle data and repair history. An exchangeable ATF filter change may not be shown automatically in the Maintenance tables. –  Clean ATF lines and ATF cooler after renewing or repairing gearbox → Chapter. –  Before installing gearbox, it is important to clean any residue from threads for engine/gearbox connection in cylinder block using a tap.

Caution Risk of leaks on ATF oil pan. Do not apply gearbox support -T40173- at ATF oil pan. –  Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- (already prepared) underneath gearbox. Gearbox support must be positioned as follows at front of gearbox: l  On left side of gearbox, mounting block -2- engages in opening for flywheel on gearbox housing. l  On right side of gearbox, use a block wrapped with elastic material -1- to apply gearbox support to centre differential housing.

–  Use tensioning strap -1- to secure gearbox.

–  The following preparations must be made before joining the engine and gearbox: –  Insert assembly aid -T40169- into gearbox housing and flywheel from below, as shown in illustration. l  The assembly tool 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 flywheel accordingly. –  Insert pin of assembly aid into hole on gearbox housing.

–  Insert transportation lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-. –  Check whether aluminium bolts for engine/gearbox connection can be reused and mark bolts if necessary → Anchor.

Vehicles with 4-cyl. petrol engine: –  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. –  Join gearbox with engine and tighten bolts -6- and -7-.

Vehicles with 6-cyl. or 8-cyl. engine: –  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves. –  Join gearbox with engine and tighten bolts -6- and -7-.

Continued for all vehicles: –  Secure tunnel cross member → Chapter.   Note The illustration does not show engine and gearbox jack -V.A.G 1383 A-. –  Lower engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- and move aside. –  Tighten engine/gearbox connecting bolts accessible from below. –  Remove transportation lock -T40170- and assembly aid -T40169-.   Note

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

Vehicles with 4-cyl. petrol engine:   Note Use ring spanner insert, 16 mm -V.A.G 1332/14-, to tighten bolts. –  Secure flywheel to drive plate as follows: –  Install first bolt -arrow- and tighten hand-tight (2 Nm).

–  Turn crankshaft at vibration damper 240° in direction of engine rotation using counterhold tool -T10355-. –  Tighten bolt accessible in this crankshaft position to specified torque → Chapter. –  Turn crankshaft 120° further each time and tighten remaining 2 bolts to specified torque → Chapter.   Note -Arrow- can be disregarded.

Vehicles with 6-cyl. engine:   Note Use ring spanner insert, 16 mm -V.A.G 1332/14-, to tighten bolts. –  Secure flywheel to drive plate as follows: –  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 at vibration damper 180° in direction of engine rotation -arrow- with adapter -T40058-. –  Tighten bolt accessible in this crankshaft position to specified torque → Chapter. –  Turn crankshaft 60° further each time and tighten remaining 5 bolts to specified torque → Chapter.

Vehicles with 8-cyl. engine:   Note Use ring spanner insert, 16 mm -V.A.G 1332/14-, to tighten bolts. –  Secure flywheel to drive plate as follows: –  Install first bolt -arrow- and tighten hand-tight (2 Nm).

–  Turn crankshaft at vibration damper 180° in direction of engine rotation -arrow- using counterhold tool -T10172- with -T10172/7-. –  Tighten bolt accessible in this crankshaft position to specified torque → Chapter. –  Turn crankshaft 60° further each time and tighten remaining 5 bolts to specified torque → Chapter. Continued for all vehicles: The remaining installation steps are carried out in reverse sequence; note the following: –  Secure intermediate steering shaft to steering box → Running gear, front-wheel and four-wheel drive; Rep. gr.48. –  Install selector lever cable → Chapter. –  Install ATF lines → Chapter. –  Secure drive shafts (left and right) to flange shafts on gearbox → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  Install heat shield for drive shaft → Fig..   Note Please refer to the vehicle data sticker or the identification on the rear final drive to find out which type of rear final drive is installed in the vehicle. Then select the appropriate Workshop Manual for the rear final drive. –  Install propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39.

Vehicles with 4-cyl. petrol engine:   Note t  Bolt -2- secures the starter to the gearbox and has an additional spacer sleeve -arrow-. t  The spacer sleeve must be fitted between the starter and the gearbox. Continued for all vehicles: –  Install starter → Electrical system; Rep. gr.27.

–  Tighten remaining gearbox/engine securing bolts -3 … 5-. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. gr.26. –  Install plenum chamber partition panel → General body repairs, exterior; Rep. gr.50. Vehicles with hydraulic power-assisted steering: –  Install hydraulic lines for power steering → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48. Continued for all vehicles: –  Install subframe cross brace → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  Install diagonal struts → Running gear, front-wheel drive and four-wheel drive; Rep. gr.42. –  Install covers for drive shaft and noise insulation panels → General body repairs, exterior; Rep. gr.66. –  Observe measures required after connecting 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. Vehicles with hydraulic power-assisted steering: –  Fill up hydraulic fluid for power steering → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48. Continued for all vehicles: –  → Chapter „Checking and correcting ATF level“. –  → Chapter „Checking gear oil level (MTF) and topping up“ 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

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

Dual clutch gearbox to 4-cyl. petrol engine

Item	Bolt	Nm
1 1)	M10x50 2)	65
2 3), 7	M12x100 4)	30 + 90°
3 5), 6	M12x75 4)	30 + 90°
4, 5 5)	M12x120 4)	30 + 90°
8, 9	M10x75 4)	15 + 90°
10	M12x50 4)	30 + 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) Also secures starter, with additional spacer sleeve between starter and gearbox. l  4) Bolts can be used twice only → Anchor. l  5) Also secures bracket for wiring.

Dual clutch gearbox to 6-cyl. petrol engine

Item	Bolt	Nm
1 1)	M10x50 2)	65
2 1), 4 … 6	M12x100 3)	30 + 90°
7	M12x125 3)	30 + 90°
8	M10x60 3)	15 + 90°
9, 10	M10x95 3)	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) Bolts can be used twice only → Anchor.

Dual clutch gearbox to 8-cyl. petrol engine (RS 5)

Item	Bolt	Nm
1 1)	M10x50 2)	65
2 1), 3, 4, 5, 6	M12x100 3)	30 +90°
7	M12x175 3)	30 +90°
8, 9, 10	M10x60 3)	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) Aluminium bolts must not be used more than twice → Anchor.

Dual clutch gearbox to 6-cyl. TDI engine

Item	Bolt	Nm
1 1)	M10x50 2)	65
2 1), 4 … 6	M12x100 3)	30 + 90°
7	M12x125 3)	30 + 90°
8	M10x60 3)	15 + 90°
9, 10	M10x95 3)	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) Bolts can be used twice only → Anchor.

t  Aluminium bolts -2 … 10- 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.