Transmission, Installing, 3.0L TFSI Engine

WARNING: This page is about a different car, the 2013 Audi S4, 2012 Audi S4, 2011 Audi S4, and 2010 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Clutch Module Assembly Aid T40169
Clutch Module Transportation Lock T40170
Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14

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 any bolts that were tightened with an additional turn.

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.

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

Check the removed manual transmission input shaft for wear grooves near the bearing in the drive plate -arrow-. If necessary, replace the needle bearing in the drive plate. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.0L, engine codes CCBA, CGXC, CTUB .

Fig 1: Checking Input Shaft For Scoring

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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 2: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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Check the aluminum engine/transmission connecting bolts -2 through 11- if they can be reused and if required, mark them. Refer to MOUNTING THE 3.0L TFSI ENGINE TO MANUAL TRANSMISSION . Checking if the Aluminum Bolts -2 through 11- Can Be Used Again.

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

Fig 3: Removing/Installing Flywheel Components

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

Fig 4: Identifying Transmission Holding Fixture

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

Fig 5: Insert 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 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.

-- Insert the pin on the handle of the Clutch Module Assembly Aid T40169 into the hole 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 6: Identifying Transportation Lock T40170

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

Fig 7: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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-- Tighten the bolt -2-. Tightening specification -item 17- OVERVIEW - CLUTCH HYDRAULICS => List Item:Bolt .

NOTE:

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

Fig 8: 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-.

-- Position the transmission on the engine and tighten the bolts -3 through 11-. Tightening specifications. Refer to MOUNTING THE 3.0L TFSI ENGINE TO MANUAL TRANSMISSION .

Fig 9: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Raise the transmission using the Engine and Gearbox Jack VAS6931 until dimension -a- is reached between the subframe and the body.

Fig 10: Lowering Transmission To Dimension -A-

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Dimension -a- = maximum 100 mm.

NOTE:

Ignore items -2 and 3-.

-- Install the starter and tighten the bolts -1- and -4-. Tightening specification. Refer to MOUNTING THE 3.0L TFSI ENGINE TO MANUAL TRANSMISSION .

Fig 11: Disconnecting Starter Electrical Connector

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-- Tighten the right catalytic converter. Refer to OVERVIEW - MUFFLER .

-- Attach the push rod -1-, refer to -item 27- Bolt (See Figure).

Fig 12: Attaching Bolts And For Selector Rod And Push Rod

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-- Attach the connecting rod -3-. Tightening specification, refer to -item 25- Bolt (See Figure).

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

-- Attach the connector to the Engine Speed Sensor -G28-.

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

Fig 13: 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 gearshift lever -2-. Tightening specification, refer to -item 18- Nut (See Figure).

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

Fig 14: Drive Axle Heat Shield & Bolts

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

-- Release the tension on the spindles of the Engine Support Bridge 10-222A.

Fig 15: Identifying Bolts & Tunnel Crossmember

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-- Lift the transmission and tighten the tunnel crossmember bolts -arrows-. Tightening specifications. Refer to OVERVIEW - SUBFRAME MOUNT .

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

-- Remove the Engine Support Bridge 10-222A.

-- Attach or install the driveshaft on the transmission. Refer to OVERVIEW - DRIVESHAFT, MOUNTED ON TRANSMISSION SIDE , and DRIVESHAFT, REMOVING AND INSTALLING, DRIVESHAFT CONNECTED ON TRANSMISSION SIDE . For Sport Differential, refer to OVERVIEW - DRIVESHAFT, MOUNTED ON TRANSMISSION SIDE , and DRIVESHAFT, MOUNTED ON TRANSMISSION SIDE, REMOVING AND INSTALLING . .

-- Assemble the exhaust system making sure it is not under stress. Refer to OVERVIEW - MUFFLER , and EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

Fig 16: Counterholding Driveshaft Using T10172 And T10172/5

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Tightening Sequence - Clutch Module to the Drive Plate, refer to Fig 20 (also see OVERVIEW - CLUTCH MODULE -item 3-).

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

-- Move into 6th gear by removing the gearshift shaft -1- and shifting the gearshift lever -2- forward in direction of -arrow-.

Fig 17: Identifying Gearshift Assembly

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-- Install both front wheels.

Block the driveshaft using the Counterhold - Multiple Use T10172A and Counterhold - Kit - Adapters 5-9 T10172/5 so it will not turn.

Fig 18: Counterholding Driveshaft Using T10172 And T10172/5

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NOTE:

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

Fig 19: 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 20: Identifying Clutch Module First Bolt Installation Location

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Use new bolts.
Tightening specification, refer to OVERVIEW - CLUTCH MODULE -item 3-.
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).

-- Turn the clutch module/drive plate an additional 180° via the front wheels.

-- Insert the second bolt and tighten it to the specification -item 3-, refer to OVERVIEW - CLUTCH MODULE -item 3-.

-- Insert the remaining bolts connecting the clutch module to the drive plate and tighten them to the specification immediately (including the first bolt installed) -item 3-, refer to OVERVIEW - CLUTCH MODULE -item 3-.

-- Attach the universal joint -arrow- to the steering gear. Refer to OVERVIEW - STEERING COLUMN -item 18- .

Fig 21: Identifying Steering Shaft Universal Joint And Bolt

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Vehicles with Hydraulic Power Steering Gear

Fig 22: Placing VAG 1782 Under Separating Point

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-- Install the power steering hydraulic lines. Refer to OVERVIEW - HYDRAULIC PIPES AND RESERVOIR .

Continuation for All Vehicles

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

-- Fill the power steering hydraulic fluid. Refer to POWER STEERING FLUID LEVEL, CHECKING .

-- Check the transmission fluid level in the manual transmission. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Tighten both front wheels to the tightening specification. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

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

CAUTION:

There is a risk of destroying control modules due to the excess voltage.

Do not use a charger to jump start.