Transmission, Installing, 4.2L FSI 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 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.

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.

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 4.2L FSI ENGINE TO MANUAL TRANSMISSION . Checking if the Aluminum Bolts -2 through 11- Can Be Used Again.

-- If necessary install the clutch module.

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: Mount Transmission Onto T40173 And Secure It Using Tension Strap

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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 4.2L FSI ENGINE TO MANUAL TRANSMISSION .

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

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-- Install the starter and tighten the bolt -1- from the engine side. Tightening specification. Refer to MOUNTING THE 4.2L FSI ENGINE TO MANUAL TRANSMISSION .

-- Then tighten the bolt -2- on the transmission side to the tightening specification. Refer to MOUNTING THE 4.2L FSI ENGINE TO MANUAL TRANSMISSION .

-- 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- = at least 100 mm.

-- Tighten the left and right drive axles on the transmission flange shafts.

Fig 11: Drive Axle Heat Shield & Bolts

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-- Install the drive axle heat shield and tighten the bolts -arrows- to 23 Nm.

-- Attach the push rod -1-. Tightening specification, 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).

-- Install the connector -2- on the Transmission Range Gear Recognition Switch -F208-.

-- 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).

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

Fig 14: Identifying Bolts & Tunnel Crossmember

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-- Remove the Engine and Gearbox Jack VAS6931 and the Gearbox Support T40173.

-- Attach or install the driveshaft on the transmission.

Fig 15: Counterholding Driveshaft Using T10172 And T10172/5

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Tightening Sequence - Clutch Module to the Drive Plate

-- 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 the direction of -arrow-.

Fig 16: Identifying Gearshift Assembly

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-- Install both front wheels.

Fig 17: Counterholding Driveshaft Using T10172 And T10172/5

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

NOTE:

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

Fig 18: 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 19: Identifying Clutch Module First Bolt Installation Location

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Use new bolts.
Tightening specification -item 3- OVERVIEW - CLUTCH MODULE => List 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- OVERVIEW - CLUTCH MODULE => List 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- OVERVIEW - CLUTCH MODULE => List Item:3 - .

Install in reverse order of removal. Note the following:

Fig 20: Identifying Steering Shaft Universal Joint And Bolt

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-- Attach the universal joint to the steering gear.

-- Install the right catalytic converter to the exhaust manifold

-- Install the left and right front muffler.

-- Align the exhaust system free of tension.

-- Install the subframe crossbrace.

-- Install the coolant connection.

-- Install the right coolant pipe.

-- Install the rear coolant pipe.

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

-- Fill the engine coolant.

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

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

-- 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.