Installing transmission on vehicles with 4.2 Liter V8 engine (S4)

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2007 Audi S4, 2007 Audi RS 4, and 2006 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Installation is performed in reverse sequence; note the following:

NOTE:

Re-attach all cable ties at the same locations when re-installing.
Secure all hose connections with the correct hose clips (as original equipment)
Re-attach heat shield sleeves at the same locations when re-installing.
Replace self-locking nuts.

Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Do not grease guide sleeve.

It should be possible to push the clutch plate back and forth slightly on the input shaft.

Fig 1: Servicing Release Bearing With Plastic Ring

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Check clutch release bearing for wear and replace if necessary.
If plastic ring - arrows - has come loose, service release bearing as required Checking and servicing release bearing with glued plastic ring .

NOTE:

The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8mm.

Lightly lubricate contact surface for operating rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.
Check that dowel sleeves for centralizing engine/transmission are in the cylinder block, install if necessary.
Place intermediate plate on dowel sleeves at engine flange.

Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between the engine and the transmission.

Fig 2: Guiding Slave Cylinder Into Bore Of Transmission Housing

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Lightly lubricate surface where operating rod and clutch release lever make contact - arrowB - using copper grease Z381351TE.
Raise transmission far enough to be able to install clutch slave cylinder with bracket for hose/line assembly.
Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.

NOTE:

If the slave cylinder - 1 - is inserted at an angle, there is a danger that the operating rod - arrow A - will be guided past the clutch release lever - 3 -.

CAUTION: After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The operating rod of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

Fig 3: Slave Cylinder Bracket And Fastener

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Secure clutch slave cylinder with new bolt - arrow -.

Fig 4: Starter And Mounting Bolts

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Insert transmission, making sure there is sufficient clearance to drive shafts.
Install starter - arrows - and tighten top left and right engine/transmission connecting bolts.

NOTE:

The bottom bolts are installed at a later stage.

Fig 5: Bracket For Front Exhaust Pipe (Left-Side) On Transmission

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Bolt bracket for front exhaust pipe (left-side) to transmission - arrows -.

Fig 6: Identifying Selector Mechanism Fasteners

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Install transmission selector lever - 2 - and tighten nut - 1 -.

Fig 7: Disconnecting/Connecting Harness Connector For Back-Up Light Switch At Right Of Transmission

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Connect connector - arrow - for reversing light switch on right side of transmission.

Fig 8: Tunnel Cross Member Nuts

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Bolt tunnel cross member onto transmission mounting - arrows -.
It is important to clean the threaded holes for driveshaft bolts to remove any remaining locking fluid. The threads can be cleaned with a thread tap.
Bolt driveshaft onto transmission → 39 FINAL DRIVE, DIFFERENTIAL .

Fig 9: Identifying Driveshaft Shield

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Bolt on heat shield for driveshaft - arrows -.

Fig 10: Removing Bolt At Strap For Right Front Exhaust Pipe

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NOTE:

The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Bolt front exhaust pipe (right-side) to bracket - arrow -.

Fig 11: Removing/Installing Nuts For Right Front Exhaust Pipe/Exhaust Manifold

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Tighten nuts - 1to3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold catalytic converter in a horizontal position).

NOTE:

Shown in illustration with engine removed.

Fig 12: Removing Bolt At Strap For Left Front Exhaust Pipe

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NOTE:

The flexible exhaust pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Bolt front exhaust pipe (left-side) to bracket - arrow -.

Fig 13: Removing/Installing Nuts For Left Front Exhaust Pipe/Exhaust Manifold

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Tighten nuts - 1 to 3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold catalytic converter in a horizontal position).

NOTE:

Shown in illustration with engine removed.

Fig 14: Freeing Up Oxygen Sensor Wires At Areas Indicated By On Transmission

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Attach oxygen sensor probe wiring to transmission at the points marked with - arrows -.

NOTE:

In the illustration the engine/transmission assembly has been removed.

Fig 15: Identifying Push Rod And Connecting Rod For Selector Rod

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Install push rod - 1 - ; to do so, tighten hexagon socket head bolt.
Secure connecting rod - 2 - for selector rod.
Bolt drive shafts to flange shafts → 40 - FRONT SUSPENSION .

Fig 16: Drive Axle Heat Shield

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Install heat shields - arrow - for drive shafts (left and right).

Fig 17: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of Wood

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Remove transmission support 3282 from engine and transmission jack V.A.G 1383 A and place a wooden block - arrow - on the lifting column in its place.
Push rear cross member upwards with engine and transmission jack V.A.G 1383 A.
Replace bolts - 1 to 4 -.
Bolt on tunnel cross member hand-tight.

Fig 18: Locating Clamping Sleeves

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Install clamps - arrows - for exhaust system.
Install exhaust system and perform stress-free alignment → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

Fig 19: Removing Front Bolts From Left And Right Subframe

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First remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
Lower subframe at the front.

Fig 20: Removing/Installing Bottom Engine/Transmission Connecting Bolts

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Tighten three bottom engine/transmission securing bolts - arrows -.

Fig 21: Removing Front Bolts From Left And Right Subframe

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Replace front subframe bolts - 1...3 - on both sides of the vehicle.

Before tightening subframe, it must be aligned with body using locating pins 3393.

Fig 22: Identifying Hole, Sub-Frame Hole And Aluminum Console Hole Align On Both Sides

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Hole - 1 - , hole - 2 - in subframe and hole - 3 - in aluminum bracket must be in alignment on both sides.

NOTE:

If this is not the case, wheel alignment will have to performed at a later stage.

Secure subframe and tunnel cross member → 40 - FRONT SUSPENSION .

Fig 23: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

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Tighten nuts - 1 - for engine mountings.

The remaining installation steps are performed in the reverse sequence; note the following points:

Check selector mechanism setting and adjust if necessary → Shift mechanism, adjusting .
Check gear oil level in transmission → Transmission gear oil, checking level .
Follow steps required after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.
Perform wheel alignment if required → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

Wheel alignment is not necessary if subframe was located in relation to body using locating pins 3393 prior to dismantling and assembly of subframe (before tightening bolts).
Wheel alignment must, however, be performed if the subframe was not located in relation to the body using locating pins 3393 or if it was not possible to fully insert the two locating pins into the holes.

NOTE:

Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
Do not use parts which have been degreased.
Tolerance for tightening torques ±15%.

Fig 24: Identifying Engine/Transmission Threaded Connections

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Engine/transmission securing bolts

Item	Bolt	Nm
1, 2	M12x120	65
3	M12x110	65
4, 5	M12x105	65
6	M12x130	65
7	M12x170	65
8, 9, 10	M10x60	45

- A - = Dowel sleeves for aligning

Tightening torques

Component	Nm
Clutch slave cylinder to transmission	23 * See note
Selector shaft lever to transmission	23* See note
Push rod to transmission	40
Connecting rod for selector rod to transmission	23
Bracket for exhaust pipe lug.	23
Transmission mounting to transmission	23
Transmission mounting to tunnel cross member	23
Heat shields above drive shafts to transmission	23
Heat shield for driveshaft to transmission cover	25
Engine mounting to engine support	23
Bracket for noise insulation to subframe	10

* Replace bolt