Transmission, Installing

Transmission, Installing

Special tools, testers and auxiliary items required

• Assembly Aid (T40169)

• Transportation Lock (T40170)

• Gearbox Support (T40173)

• Spindles (10 - 222 A /11)

• Ring Spanner Insert AF16 (V.A.G 1332/14)

• Hose Clamps Up to 25 mm in Dia. (3094)

Procedure

• Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times.

• Replace self-locking nuts and bolts and seals, gaskets and O-rings.

• Secure all hose connections with hose clamps of the same type as those equipped by the factory, refer to the Parts Catalog.

• When installing, bring all cable ties back to the same positions.

Transmission installation tightening specifications.

- Mount the transmission onto the (T40173) and secure it using the tension strap - 1 - as illustrated.






- Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate if necessary.






- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.






• See if it is possible to use the aluminum bolts - 2 through 11 - again and mark them if necessary.

- Installing the clutch module if necessary.






- The following preparations must be made before connecting the engine and transmission:






- Insert the (T40169) in the transmission housing and the clutch module from below as shown in the illustration.

• The (T40169) must engage in the semi-circular opening - 1 - and into the check hole - 2 -.

• There is only 1 inspection opening on the circumference. Rotate the clutch module as needed.

- Install the bolts from the assembly device into the holes on the transmission housing.

- Insert the (T40170) in the transmission housing from below and secure it on the flange shaft - 1 -.






- Raise the transmission straight up until the clutch slave cylinder - 1 - can be inserted.






- Tighten bolt - 2 -. Tightening specification - item 17 - => [ (Item 17) Bolt ] Removal and Replacement.

• The next step is only necessary if a drive plate with alignment pins - 2 - is installed.






- Align the drive plate to the clutch module so the alignment pins - 2 - on the drive plate (if applicable) can engage in the larger holes - 1 - on the clutch module.


The clutch will not function properly if it is not installed correctly.

• The clutch may have noticeable function problems if the alignment pins for the drive plate - 2 - are not in the holes in the clutch module - 1 -.

- Connect the transmission to the engine and tighten - 3.... 11 - the bolts. Tightening specifications.






- Insert the starter and tighten the bolt - 3 - manually from the engine side out.






- Install the spacer sleeve - 2 - between the starter and transmission, push the bolt - 1 - through and tighten.

- Tighten the starter bolts - 1 and 3 -. Tightening specifications.

- Raise the transmission using the (V.A.G 1383 A) until dimension - a - is reached between the subframe and the body.






• - a - = minimum 80 mm

- Attach the push rod - 1 - - item 27 - => [ (Item 27) Bolt ] Selector Mechanism Overview.






- Attach the connecting rod - 3 -. Tightening specification - item 25 - => [ (Item 25) Bolt ] Selector Mechanism Overview.

- Connect the connector - 2 - to the transmission range gear recognition switch (F208) or the gear recognition sensor (G604).

Install the transmission shift lever - 2 - as follows:






• The gearshift lever - 2 - can be attached to the gearshift shaft - 1 - in only one position (gap in the splines - arrow -).

- Tighten the selector lever. Tightening specification - item 18 - => [ (Item 18) Nut ] Selector Mechanism Overview.

- Connect the connector to the transmission neutral position sensor (G701) - 1 -.






- Loosen the (10 - 222 A /11).






- Lift the transmission further and tighten the bolts - arrows - on the tunnel crossmember. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.






- Remove the (V.A.G 1383 A) and (T40173).

- Attach the left and right drive axles to the transmission flange shafts.






- Install the driveshaft heat shield. Refer to => [ Drive Axle Heat Shield - Tightening Specification ].






- Install the subframe shield on the left and right side.

- Secure the driveshaft on the transmission.






Block the driveshaft. To do this, place the (T10172) and (T10172/5) on the driveshaft bolts on the transmission or the rear final drive.

Tightening Sequence - Clutch Module to the Drive Plate






- Remove the (T40169) and (T40170).

- Remove the gearshift shaft - 1 - and then move the gearshift lever - 2 - forward in direction of - arrow - into 6th gear.

• The following step is absolutely necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.






- Turn both front wheel together in one direction until the clutch module turns one complete turn (360°).

• The check hole - arrow - must be visible in the transmission housing cut-out.

Tighten the clutch module to the drive plate as follows:






• Use new bolts.

• Tighten the bolts using the (V.A.G 1332/14).

- Install the first bolt - arrow - and tighten by hand (2 Nm).

- Rotate the clutch module 120° further in the direction of engine rotation with the front wheels and install the second bold and tighten by hand (2 Nm).

- Rotate the clutch module 120° in the direction of engine rotation again.

- Install the third bolt and tighten it.

- Tighten the remaining two bolts.

Install in reverse order of removal. Note the following:






- Install the driveshaft heat shield - A - and tighten the bolts - arrows - to 25 Nm, if equipped.

- Install the exhaust system so that it is free of tension.

Vehicles with Transmission Fluid Heater






- Connect the coolant hoses to the connections on the transmission and secure them with the spring clamps - 1 -.

- Remove the (3094).

- Fill with coolant.

All Vehicles






- Attach the steering intermediate shaft to the steering gear.

- Install the subframe crossbrace.






- Gear oil level in manual transmission, checking. Refer to => [ Transmission Fluid Level, Checking ] Service and Repair.

- Install the noise insulation.

- Complete the steps required after connecting the battery.


Danger of causing damage to the control modules due to the excess voltage.

• Do not use a charger to jump start!

Tightening Specifications

• The tightening specifications apply only 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 any ungreased parts.

• Tightening specification tolerance ± 15%.






Drive Axle Heat Shield - Tightening Specification





- Tighten the heat shield bolts - arrows - to 23 Nm.

Securing the Engine to the Manual Transmission











• Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts - 2 through 11 - may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time - arrow -.






• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.

• Bolts marked with an "X" may not be used again.

• Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.

• Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.