Installing Transmission

Installing transmission on vehicles with 4.2 Liter V8 engine (S4), 0A3, 6 Spd. M/T AWD

Installation is performed in reverse sequence; note the following:

Note:
^ Re-attach all cable ties at the same locations when re-installing.
^ Secure all hose connections with the correct hose clips (as original equipment); refer to Parts catalog.
^ Re-attach heat shield sleeves at the same locations when reinstalling.
^ Replace self-locking nuts.

- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Do not grease guide sleeve.
^ It should be possible to push the clutch plate back and forth slightly on the input shaft.





- Check clutch release bearing for wear and replace if necessary.
- If plastic ring - arrows - has come loose, service release bearing as required.

Note:
^ The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8 mm.

- Lightly lubricate contact surface for operating rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
- Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.
- Check that dowel sleeves for centralizing engine/transmission are in the cylinder block, install if necessary.
- Place intermediate plate on dowel sleeves at engine flange.
- Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between the engine and the transmission.





- Lightly lubricate surface where operating rod and clutch release lever make contact - arrowB - using copper grease Z381351TE.
- Raise transmission far enough to be able to install clutch slave cylinder with bracket for hose/line assembly.
- Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.

Note:
^ If the slave cylinder - 1 - is inserted at an angle, there is a danger that the operating rod - arrow A - will be guided past the clutch release lever - 3 -.

CAUTION: After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The operating rod of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approximately 300 N.





- Secure clutch slave cylinder with new bolt - arrow -.





- Insert transmission, making sure there is sufficient clearance to drive shafts.
- Install starter - arrows - and tighten top left and right engine/transmission connecting bolts.

Note:
^ The bottom bolts are installed at a later stage.





- Bolt bracket for front exhaust pipe (left-side) to transmission - arrows -.





- Install transmission selector lever - 2 - and tighten nut - 1 -.





- Connect connector - arrow - for reversing light switch on right side of transmission.





- Bolt tunnel cross member onto transmission mounting - arrows -.
- It is important to clean the threaded holes for driveshaft bolts to remove any remaining locking fluid. The threads can be cleaned with a thread tap.

- Bolt driveshaft onto transmission.





- Bolt on heat shield for driveshaft - arrows -.





Note:
^ The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

- Bolt front exhaust pipe (right-side) to bracket - arrow -.





- Tighten nuts - 1 to 3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold catalytic converter in a horizontal position).

Note:
^ Shown in illustration with engine removed.





Note:
^ The flexible exhaust pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° otherwise it can be damaged

- Bolt front exhaust pipe (left-side) to bracket - arrow -.





- Tighten nuts - 1 to 3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold catalytic converter in a horizontal position).

Note:
^ Shown in illustration with engine removed.





- Attach oxygen sensor probe wiring to transmission at the points marked with - arrows -.

Note:
^ In the illustration the engine/transmission assembly has been removed.





- Install push rod - 1 -; to do so, tighten hexagon socket head bolt.
- Secure connecting rod - 2 - for selector rod.
- Bolt drive shafts to flange shafts.





- Install heat shields - arrow - for drive shafts (left and right).





- Remove transmission support 3282 from engine and transmission jack V.A.G 1383 A and place a wooden block - arrow on the lifting column in its place.
- Push rear cross member upwards with engine and transmission jack V.A.G 1383 A.
- Replace bolts - 1 to 4-.
- Bolt on tunnel cross member hand-tight.





- Install clamps - arrows - for exhaust system.
- Install exhaust system and perform stress-free alignment.





- First remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
- Lower subframe at the front.





- Tighten three bottom engine/transmission securing bolts - arrows -.





- Replace front subframe bolts - 1...3 - on both sides of the vehicle.
Before tightening subframe, it must be aligned with body using locating pins 3393.





- Hole - 1 -, hole - 2 - in subframe and hole - 3 - in aluminum bracket must be in alignment on both sides.

Note:
^ If this is not the case, wheel alignment will have to performed at a later stage.

- Secure subframe and tunnel cross member.





- Tighten nuts - 1 - for engine mountings.
The remaining installation steps are performed in the reverse sequence; note the following points:
- Check selector mechanism setting and adjust if necessary.
- Check gear oil level in transmission.
- Follow steps required after connecting battery.
- Perform wheel alignment if required.
^ Wheel alignment is not necessary if subframe was located in relation to body using locating pins 3393 prior to dismantling and assembly of subframe (before tightening bolts).
^ Wheel alignment must, however, be performed if the subframe was not located in relation to the body using locating pins 3393 or if it was not possible to fully insert the two locating pins into the holes.

Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant
^ Do not use parts which have been degreased.
^ Tolerance for tightening torques ± 15%.





Engine/transmission securing bolts

Engine/transmission securing bolts:

- A - = Dowel sleeves for aligning.

Tightening Torque: