Transmission, Installing, AUDI Q5 With 2.0L TFSI Engine And 4-Cylinder TDI Engine, (Pr-Th3/TM4)

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
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Clutch Module Transportation Lock T40170

Fig 2: Clutch Module Transportation Lock T40170
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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

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-- 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

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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

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

Fig 6: Inserting Assembly Aid T40169 Into Transmission Housing

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-- 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 T40169 must 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

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-- 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: Identifying Engine To Transmission Bolts And Alignment Sleeves

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See if it is possible to use the aluminum bolts -2 through 11- again and mark them if necessary. Refer to Mounting 2.0L TDI engine on the manual transmission or Mounting 2.0L TFSI engine on the manual transmission .

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

Fig 9: Raising Transmission Straight Up Until Clutch Slave Cylinder Can Be Inserted

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

NOTE:

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

Fig 10: Aligning Drive Plate To Clutch Module

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-- 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.

CAUTION:

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-.

-- Place the transmission on the engine and tighten the bolts -7 through 11- that connect the engine to the transmission. Tightening specifications. Refer to TRANSMISSION TIGHTENING SPECIFICATION, AUDI Q5 .

Fig 11: Identifying Engine To Transmission Bolts And Alignment Sleeves

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NOTE:

The bolt -7- is only installed on 4-cylinder TDI engines.

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

Fig 12: Identifying Starter Bolts And Spacer

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-- 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. Refer to TRANSMISSION TIGHTENING SPECIFICATION, AUDI Q5 .

-- Tighten remaining bolts connecting the engine to the transmission. Tightening specifications. Refer to TRANSMISSION TIGHTENING SPECIFICATION, AUDI Q5 .

-- Tighten the tunnel crossmember bolts -arrows-. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 13: Identifying Tunnel Crossmember And Bolts

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-- Install the transmission shift lever -2- as follows:

Fig 14: Gearshift Lever Can Be Attached To The Gearshift Shaft In Only One Position

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

Fig 15: Installing Connector On Transmission Range Gear Recognition Switch

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

-- Connect the connector -2- to the Transmission Range Gear Recognition Switch -F208- or the Gear Recognition Sensor -G604- and lock if necessary.

-- Connect the connector to the Transmission Neutral Position Sensor -G701- -1-.

Fig 16: Locating Transmission Neutral Position Sensor (Through MY 2012)

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-- If equipped clip the bracket -B- and connector the connector -C- for Exhaust Gas Temperature Sensor 4 -G648- to the transmission.

Fig 17: Unclip Wiring From Transmission

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-- Attach the electrical wire -A- to the transmission -arrows-.

-- Tighten the driveshafts on the transmission flange shafts. Refer to DRIVE AXLE .

Fig 18: Identifying Left And Right Drive Axles

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

Fig 19: Drive Axle Heat Shield & Bolts

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-- If equipped, install the right subframe shield.

-- Install the noise insulation -1- in the right wheel housing.

Fig 20: Driveshaft Cover -1-

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-- 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

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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 transmission or the rear final drive.

Tightening sequence - clutch module to the drive plate

Fig 22: Identifying Gearshift Assembly

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

-- 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 necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.

Fig 23: Locating Transmission Housing Check Hole

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-- 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

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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:

Fig 25: Identifying Driveshaft Heat Shield

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

Vehicles with a 2.0L TDI engine

-- Install the particulate filter and the front exhaust pipe. 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 .

-- Install the air filter housing. .

Vehicles with hydraulic power steering gear

Fig 26: Removing/Installing Hydraulic Oil Line At Steering Gear

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-- Install the power steering hydraulic lines. Refer to STEERING GEAR .

Vehicles with transmission fluid heater

Fig 27: Identifying Coolant Hoses And Hose Clamps 3094

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-- 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.

-- 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 .

Continuation for all vehicles

Fig 28: Pressing CV Joint Off Steering Gear And Slide It Up

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

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

Fig 29: Identifying Bolt From Power Steering Line

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

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

-- Install the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- 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.