Transmission, Installing, AUDI A4, A5, Q5 With 4-Cylinder TDI Engine (Ea288 Gen I), Pr-TD1

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Clutch Module Assembly Aid T40169

Fig 1: Clutch Module Assembly Aid T40169
Courtesy of AUDI OF AMERICA, LLC
Clutch Module Transportation Lock T40170

Fig 2: Clutch Module Transportation Lock T40170
Courtesy of AUDI OF AMERICA, LLC

Procedure

NOTE:

Replace any bolts that were tightened with an additional turn. 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.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

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.

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

Fig 3: Identifying Transmission Holding Fixture

Courtesy of AUDI OF AMERICA, LLC

-- Check the input shaft near the bearing in the drive plate -arrow- for wear grooves and replace the needle bearing in the drive plate if necessary.

Fig 4: Checking Input Shaft For Scoring

Courtesy of AUDI OF AMERICA, LLC

Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.0L, engine codes CCBA, CGXC, CTUB, or NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.2L, engine code CALA .

-- If necessary install the clutch module. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

Fig 5: Removing/Installing Flywheel Components

Courtesy of AUDI OF AMERICA, LLC

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

Fig 6: Inserting Assembly Aid T40169 Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Clutch Module Assembly Aid T40169 from below between the transmission housing and the clutch module as shown in the illustration.

The Clutch Module Assembly Aid T40169must engage in the semi-circular opening -1- and into the check hole -2-.

NOTE:

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 Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 7: Identifying Transportation Lock T40170

Courtesy of AUDI OF AMERICA, LLC

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

Fig 8: Engine To Transmission Bolts And Alignment Sleeves

Courtesy of AUDI OF AMERICA, LLC

If necessary, check and mark the aluminum bolts -2 through 10- for connecting the engine to the transmission if they can be reused.

-- Install the for the upper starter bolt -2- on the transmission and slide on the spacer sleeve -arrow-.

Fig 9: Identifying Upper Starter Bolt And Spacer Sleeve

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The spacer sleeve -arrow- cannot be installed after the transmission is installed.

The spacer sleeve -arrow- must be in the installation position when installing the transmission.

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

Fig 10: Raising Transmission Straight Up Until Clutch Slave Cylinder Can Be Inserted

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolt -2-. Tightening specification, refer to OVERVIEW - CLUTCH HYDRAULICS -item 17- Bolt.

-- Place the transmission on the engine and tighten the bolts -3 through 10- that connect the engine to the transmission.

Fig 11: Engine To Transmission Bolts And Alignment Sleeves

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The bolts -3- and -5- can also attach the wire bracket.

-- Install the starter and install the bolt -1- hand-tight.

Fig 12: Identifying Starter Bolts And Spacer

Courtesy of AUDI OF AMERICA, LLC

The spacer sleeve -2- is located between the starter and the transmission.

-- Install the starter bolt -3-.

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

Install the selector lever as follows:

Fig 13: Gearshift Lever Can Be Attached To The Gearshift Shaft In Only One Position

Courtesy of AUDI OF AMERICA, LLC

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: refer to -item 18- Nut.

-- Attach all wires back into their original position on the transmission.

Fig 14: Attaching Bolts And For Selector Rod And Push Rod

Courtesy of AUDI OF AMERICA, LLC

-- Connect the connector -2- on the Gear Recognition Sensor -G604-

-- Attach the push rod -1-, refer to 27- Bolt.

-- Attach the connecting rod -3-, refer to -item 25- Bolt.

-- Remove the Brake Piston Retraction Tool T40142.

Fig 15: Identifying Torque Support And Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the bolts -1- for the torque support -2-.

-- Raise the transmission and tighten the tunnel crossmember bolts -arrows-. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 16: Identifying Tunnel Crossmember And Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the Engine and Gearbox Jack VAS6031 with the Gearbox Support T40173 from the bottom of the transmission.

-- Slide the torque support -1- all the way onto the crossmember in the -direction of arrow-.

Fig 17: Pushing Torque Support -1- All Way Onto Crossmember -Arrow-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The stop buffer -2- must lie on the crossmember without any play or tension.

-- Tighten the bolts -3- to the tightening specification.

Vehicles with transmission fluid heater

Fig 18: Identifying Coolant Hoses And Hose Clamps 3094

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the Hose Clamps - Up To 25mm 309494.

Continuation for all vehicles

Fig 19: Identifying Left And Right Drive Axles

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the left and right drive axles on the transmission flange shafts. Refer to DRIVE AXLE .

-- Install the driveshaft heat shield, (See Figure).

Fig 20: Drive Axle Heat Shield & Bolts

Courtesy of AUDI OF AMERICA, LLC

-- If equipped install the right and left subframe shield. Refer to OVERVIEW - SUBFRAME .

-- Install the driveshaft or secure to the transmission. Refer to DRIVESHAFT or 39 FINAL DRIVE, DIFFERENTIAL for Sport Differential.

Fig 21: Counterholding Driveshaft Using T10172 And T10172/5

Courtesy of AUDI OF AMERICA, LLC

Block the driveshaft. To do this, place the Counterhold - Kit - Multiple Use T10172 and Counterhold - Kit - Adapter 5 T10172/5 on the driveshaft bolts on the rear final drive.

Tightening sequence - clutch module to the drive plate

Fig 22: Identifying Gearshift Assembly

Courtesy of AUDI OF AMERICA, LLC

-- Remove the Clutch Module Transportation Lock T40170 and the Clutch Module Assembly Aid T40169.

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

NOTE:

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

Fig 23: Locating Transmission Housing Check Hole

Courtesy of AUDI OF AMERICA, LLC

-- 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:

Fig 24: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

Use new bolts.
Tightening specification, refer to OVERVIEW - CLUTCH MODULE -Item 3- Bolt.
Tighten the bolts using the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14.

-- 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. Tightening specification, refer to OVERVIEW - CLUTCH MODULE -Item 3- Bolt.

-- Tighten the remaining two bolts. Tightening specification, refer to OVERVIEW - CLUTCH MODULE -Item 3- Bolt.

Install in reverse order of removal. Note the following:

-- Assemble the exhaust system making sure it is not under stress. Refer to EXHAUST PIPES/MUFFLERS for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, EXHAUST PIPES/MUFFLERS for 3.0L, engine codes CCBA, CGXC, CTUB, or EXHAUST PIPES/MUFFLERS for 3.2L, engine code CALA .

-- Attach the steering intermediate shaft to the steering gear. Refer to OVERVIEW - STEERING COLUMN and OVERVIEW - STEERING GEAR .

Fig 25: Pressing CV Joint Off Steering Gear And Slide It Up

Courtesy of AUDI OF AMERICA, LLC

-- Install the subframe crossbrace. Refer to OVERVIEW - SUBFRAME .

Fig 26: Identifying Subframe Crossbrace

Courtesy of AUDI OF AMERICA, LLC

A5 Cabriolet:

-- Install the left and right crossmember. Refer to OVERVIEW - SUBFRAME .

All vehicles:

-- Gear oil level in manual transmission, checking TRANSMISSION FLUID LEVEL, CHECKING .

-- Install the noise insulations. Refer to OVERVIEW - NOISE INSULATION .

-- Secure the bracket for the Exhaust Pressure Sensor 1 -G450- und Differential Pressure Sensor -G505- with the bolt -3-. Tightening specification: 8 Nm.

Fig 27: Identifying Connectors -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- Connect the connectors -1 and 2-.

-- Fill the engine coolant. Refer to COOLANT, DRAINING AND FILLING for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, COOLANT, DRAINING AND FILLING for 3.0L, engine codes CCBA, CGXC, CTUB, or COOLANT, DRAINING AND FILLING for 3.2L, engine code CALA .

-- Install the engine cover.

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger to jump start.