Transmission, Installing
Transmission, Installing
Special tools, testers and auxiliary items required
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Gearbox Support (T40173)
• Engine-/Gearbox Jack (V.A.G 1383 A) Spindles (10 - 222 A /11)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Ring Spanner Insert AF16 (V.A.G 1332/14)
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• 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.
• To secure the charge air hoses on their connections, spray the clamps used previously with rust remover before installing.
• When installing, bring all cable ties back to 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 the 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.
- Also 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.
- Install the starter and tighten the bolts - 1 and 4 -. Tightening specification.
- Raise the transmission using the (V.A.G 1383 A) until dimension - a - is reached between the subframe and the body.
• - a - = minimum 100 mm (3.93 inches)
- 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).
- 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 -).
- Attach the transmission shift lever - 2 -. Tightening specification - item 18 - => [ (Item 18) Nut ] Selector Mechanism Overview.
- Loosen the (10 - 222 A /11).
- Lift the transmission and tighten the tunnel crossmember bolts - arrows -. Tightening specifications, 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).
- Install the left and right drive axles on the transmission flange shafts.
- Install the drive axle heat shield. Refer to => [ Drive Axle Heat Shield - Tightening Specification ].
- Install the driveshaft.
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).
- Turn the clutch module 180° in engine direction of rotation over both front gears.
- Insert the second bolt and tighten it.
- Install the remaining bolts and tighten them (and the one bolt that was installed earlier).
Install in reverse order of removal. Note the following:
- Tighten the universal joint on the steering gear.
- Install the driveshaft heat shield - A - and tighten the bolts - arrows - to 25 Nm, if equipped.
- Install the right catalytic converter.
- Install the left and right front muffler.
- Install the exhaust system so that it is free of tension.
- Install the subframe crossbrace.
- Gear oil level in manual transmission, checking. Refer to => [ Transmission Fluid Level, Checking ] Service and Repair.
- Install the noise insulation.
- Install the bulkhead plenum chamber.
- Observe measures 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.