3.0 TFSI
Transmission, Installing
Special tools, testers and auxiliary items required
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Ring Spanner Insert AF16 (V.A.G 1332/14)
• Transmission Support (T40173)
• Engine/Transmission Jack (V.A.G 1383 A)
• Engine Support Bridge (10 - 222 A)
• Ring Spanner Insert AF 16 (V.A.G 1332/14)
Installing
• 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 bolts that are tightened to the specification.
• 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 electronic parts catalog ETKA.
• When installing, bring all cable ties back to the same positions.
• Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate, if necessary.
Transmission Installation Tightening Specifications:
- 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.
- Install the clutch module, if necessary.
- Mount the transmission onto the (T40173) and secure it using the tension strap - 1 - as illustrated.
- 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 (T40169) 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 can be inserted.
- Tighten the bolt - 2 -. Tightening specification => [ (Item 17) Bolt ] Description and Operation.
• 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 -.
- Attach the transmission to the engine and tighten the bolts - 3 through 11 -.
- Raise the transmission using the (V.A.G 1383 A) until dimension - a - is reached between the subframe and the body.
• Dimension - a - = maximum 100 mm.
- Install the starter and tighten the bolts - 1 - and - 4 -. Tightening specification.
• Ignore - 2 through 3 -.
- Tighten the right catalytic converter.
- Attach the push rod - 1 - => [ (Item 27) Bolt ] Selector Mechanism Overview.
- Attach the connecting rod - 3 -. Tightening specification => [ (Item 25) Bolt ] Selector Mechanism Overview.
- Connect the connector - 2 - to the transmission range gear recognition switch (F208).
- Attach the connector to the engine speed sensor (G28).
- 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) Nut ] Selector Mechanism Overview.
- Install the left and right drive axles on the transmission flange shafts.
- Tighten the heat shield bolts - arrows - to 23 Nm.
- Loosen the (10 - 222 A) spindles.
- Lift the transmission and tighten the tunnel crossmember bolts - arrows -. For the correct 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 the (T40173) from the transmission.
- Remove the (10 - 222 A).
- Mount or install the driveshaft on the transmission.
- Re-assemble the exhaust system and ensure it is not under stress.
Tightening Sequence - Clutch Module to the Drive Plate
- Remove the (T40169) and (T40170).
- Put in sixth gear; to do this, move the gearshift shaft - 1 -, push the gearshift lever - 2 - forward in direction of - arrow -.
- Mount both front wheels.
Use the (T10172) and adapter (T10172/5) to block the driveshaft to keep it from turning, too.
• 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 wheels 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).
- Continue turning the clutch module/drive plate 180° via the front wheels.
- Insert the second bolt and tighten it to the specification.
- Insert the remaining connecting bolts connecting the clutch module to the drive plate and tighten them to the specification immediately (including the first bolt installed).
- Tighten the universal joint - arrow - to the steering gear.
- Install the power steering hydraulic oil lines.
- Install the subframe crossbrace.
- Fill the power steering with hydraulic oil.
- Gear oil level in manual transmission, checking. Refer to => [ Manual Transmission, Checking Transmission Fluid Level ] Service and Repair.
- Tighten down both front wheels using tightening torque.
- Observe measures after connecting the battery.
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.
• Do not use any ungreased parts.
• Tightening specification tolerance ± 15%.
Mounting 3.0L TFSI engine on Manual Transmission
Check the aluminum bolts - 2 through 11 - to see whether they can be reused.
• Audi A4 from VIN 8K-9-066500, Audi A5 from VIN 8T-9-008000: The aluminum bolts (refer to figure) 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.
• There is no limit to the number of times the steel bolt can be used again.