Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 2.7 ltr. TDI engine 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- 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 hoses for charge air system 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 charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. 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 lines 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. –  Attach bracket -1- for exhaust system mounting to new gearbox → Engine, mechanics; Rep. gr.26.

–  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 dual-mass flywheel 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 dual-mass flywheel 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 -7 … 11-. –  Take out retainer -T40170- (transport lock) and assembly aid -T40169-.

–  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 dual-mass flywheel makes even and proper contact on the drive plate and does not cant. –  Slightly press dual-mass flywheel -2- against drive plate -3- in direction of -arrow- using a suitable lever -1-.

–  Secure dual-mass 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 60 Nm. –  Turn crankshaft 60° further each time and tighten remaining five bolts to 60 Nm. 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..

–  Tighten remaining gearbox/engine securing bolts -3 … 5-. –  Install particulate filter and front exhaust pipe → Engine, mechanics; Rep. gr.26. –  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 noise insulation panels → General body repairs, exterior; Rep. gr.66. –  Observe measures which have to be taken after connecting the 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 ATF level and top up as required → Chapter. –  After performing repair work on gearbox, check gear oil level in front final drive and top up if necessary → 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 is ± 15 %.

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65
Dual-mass flywheel to drive plate			60 1)
l  1) Renew bolts.

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 1)	M10x50 2)	65
2 3) … 6	M12x100 4)5)	30 + 90°
7	M12x125 4)5)	30 + 90°
8, 11	M10x60 4)5)	15 + 90°
9, 10	M10x95 4)5)	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) Also secures starter. l  4) Audi A4 vehicles up to vehicle identification no. 8K-9A-066499, Audi A5 vehicles up to vehicle identification no. 8T-9A-007999: renew aluminum bolts. l  5) Audi A4 vehicles from vehicle identification no. 8K-9A-066500 onwards, Audi A5 vehicles from vehicle identification no. 8T-9A-008000: aluminium bolts can be used twice only → Anchor.

t  Audi A4 vehicles from vehicle identification no. 8K-9A-066500 onwards, Audi A5 vehicles 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.