Transmission, Installing, AUDI A4, A5 With 3.2L FSI Engine

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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.

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 .

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

Fig 5: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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See if it is possible to use the aluminum bolts -2 through 11- again and mark them if necessary.

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

Fig 6: Removing/Installing Flywheel Components

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

Fig 7: 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 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 8: Identifying Transportation Lock T40170

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-- 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-.

-- Position the transmission on the engine and tighten the bolts -3 through 11-.

Fig 11: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Install the starter and tighten the bolts -1 and 4-..

Fig 12: Disconnecting Starter Electrical Connector

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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 13: Engine And Gearbox Jack VAS 6931

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Dimension -a- = at least 100 mm.

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

Fig 14: 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.

-- Connect the connector -2- to the Transmission Range Gear Recognition Switch -F208-.

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

Fig 15: 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.

-- Loose the Engine Support Bridge - Spindle 10-222A/11

Fig 16: Identifying Additional Engine Support Bridge 10-222A

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

Fig 17: Identifying Tunnel Crossmember And Bolts

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

-- Tighten the left and right 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. Refer to Figure.

Fig 19: Drive Axle Heat Shield & Bolts

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

Fig 20: Counterholding Driveshaft Using T10172 And T10172/5

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

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

Fig 22: 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 23: 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).

-- Turn the clutch module 180° in engine direction of rotation over both front gears.

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

-- Install the remaining bolts and tighten them (and the one bolt that was installed earlier). Tightening specification, refer to OVERVIEW - CLUTCH MODULE -Item 3- Bolt.

Install in reverse order of removal. Note the following:

Fig 24: Pressing CV Joint Off Steering Gear And Slide It Up

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-- Attach the universal joint to the steering gear. Refer to OVERVIEW - STEERING COLUMN and OVERVIEW - STEERING GEAR .

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

Fig 25: Identifying Driveshaft Heat Shield

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-- Install the right catalytic converter. Refer to EMISSIONS CONTROL for 3.2L, engine code CALA, EMISSIONS CONTROL for 3.0L, engine codes CCBA, CGXC, CTUB, or CATALYTIC CONVERTER, REMOVING AND INSTALLING for 2.0L, engine codes CAED, CAEB, CPMB, CPMA. .

-- Install the left and right front muffler. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, or FRONT MUFFLER, REMOVING AND INSTALLING for 3.0L, engine codes CCBA, CGXC, CTUB, or FRONT MUFFLER, REMOVING AND INSTALLING for 3.2L, engine code CALA .

-- Align the exhaust system free of tension. 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 subframe crossbrace. Refer to OVERVIEW - SUBFRAME .

Fig 26: 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 plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- 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.