Transmission, Installing, AUDI A4, A5 With 4-Cylinder TDI Engine, Pr-Th3/TM4

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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.

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 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 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: Engine To Transmission Bolts And Alignment Sleeves

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See if it is possible to use the aluminum bolts -2 through 10- again and mark them if necessary.

-- 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 10- that connect the engine to the transmission..

Fig 11: Engine To Transmission Bolts And Alignment Sleeves

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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 12: Engine And Gearbox Jack VAS 6931

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Dimension -a- = minimum 80 mm

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

Fig 13: 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 install.

-- Tighten the starter bolts -1- and -3-..

NOTE:

Install the bolt -1- and spacer sleeve -2- from above, over the plenum chamber bulkhead that has been removed.

To do so use the Step Ladder VAS5085.

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

Fig 14: Unclip Wiring From Transmission

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

-- Attach all wires back into their original position on the transmission.

Fig 15: Locating Transmission Neutral Position Sensor (Through MY 2012)

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

Fig 16: Attaching Bolts And For Selector Rod And Push Rod

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

Install the selector lever as follows:

Fig 17: 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 18: Installing 10-222A With 10-222A /3 On Left And Right Strut Towers

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

Fig 19: Identifying Tunnel Crossmember And Bolts

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-- 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.

-- Install the remaining bolts -3 ••• 6- for connecting the engine to the transmission and tighten.

Fig 20: Engine To Transmission Bolts And Alignment Sleeves

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NOTE:

The bolts -3- and -5- also attach the wire bracket.

-- Install the connecting rod -3- from the top, above the removed plenum chamber bulkhead. Refer to OVERVIEW - SELECTOR MECHANISM .

Fig 21: Attaching Bolts And For Selector Rod And Push Rod

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NOTE:

Ignore -2- and -3-.

-- Slide the torque support -1- all the way onto the crossmember in the -direction of arrow-.

Fig 22: Pushing Torque Support -1- All Way Onto Crossmember -Arrow-

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NOTE:

The stop buffer -2- must lie on the crossmember without any play or tension.

-- Tighten the bolts -3- to the tightening specification. .

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

Fig 23: Identifying Left And Right Drive Axles

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-- Install the driveshaft heat shield Figure.

Fig 24: Drive Axle Heat Shield & Bolts

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-- Install the subframe shield on the left and right side.

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

Fig 25: 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 26: Identifying Gearshift Assembly

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

-- 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 27: 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 28: 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.

Vehicles with transmission fluid heater

Fig 29: 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.

Continuation for all vehicles

Install in reverse order of removal. Note the following:

-- Assemble the exhaust system making sure it is not under stress. 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 plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- If equipped install the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- If necessary, install the air filter housing. .

-- 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 .

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

Fig 30: Identifying Driveshaft Heat Shield

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

Fig 31: Pressing CV Joint Off Steering Gear And Slide It Up

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

Fig 32: Identifying Bolt From Power Steering Line

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A5 Cabriolet:

-- Install the left and right crossmember. Refer to OVERVIEW - SUBFRAME .

All vehicles:

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

-- 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 with excess voltage.

Do not use a charger to jump start.