Transmission, Installing: Notes

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2013 Audi S5, 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, and 2009 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Assembly Aid T40169
Transportation Lock T40170
Ring Spanner Insert AF 16 V.A.G 1332/14
Transmission Support T40173
Engine/Transmission Jack V.A.G 1383 A
Engine Support Bridge 10 - 222 A
Ring Spanner Insert AF 16 V.A.G 1332/14

Special Tools And Workshop Equipment Required

Assembly Aid T40169
Transportation Lock T40170
Ring Spanner Insert AF16 V.A.G 1332/14
Transmission Support T40173
Engine/Transmission Jack V.A.G 1383 A
Counterhold Tool Touareg V10 T10172 with Adapter T10172/5
Engine Support Bridge 10 - 222 A
Ring Spanner Insert AF 16 V.A.G 1332/14

Procedure

NOTE:

Replace bolts that are tightened to the specification. 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 the same positions.

Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate, if necessary. Refer to INPUT SHAFT OVERVIEW - Needle Bearing .

Fig 1: Checking Input Shaft For Wear

Courtesy of AUDI OF AMERICA, LLC

Transmission Installation Tightening Specifications: TIGHTENING SPECIFICATIONS

-- 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: Removing Starter Off Transmission And Leave It In Installation Position

Courtesy of AUDI OF AMERICA, LLC

See if it is possible to use the aluminum bolts -2 through 11- again and mark them, if necessary. CHECK THE ALUMINUM BOLTS -2 THROUGH 11- TO SEE WHETHER THEY CAN BE REUSED. .

-- Install the clutch module, if necessary. Refer to CLUTCH MODULE .

Fig 3: Sliding Torque Converter Carefully Onto Input Shaft

Courtesy of AUDI OF AMERICA, LLC

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

Fig 4: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

Courtesy of AUDI OF AMERICA, LLC

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

Fig 5: Inserting Assembly Aid T40169 Into Transmission Housing And Flywheel From Below

Courtesy of AUDI OF AMERICA, LLC

-- Insert the T40169 in the transmission housing and the clutch module from below as shown in the illustration.

The T40169 must 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 T40169 into the holes on the transmission housing.

-- Insert the T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 6: Identifying Transportation Lock T40170

Courtesy of AUDI OF AMERICA, LLC

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

Fig 7: Removing Bolt And Secure Clutch Slave Cylinder Sideways In Engine Compartment

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolt -2-. Tightening specification CLUTCH HYDRAULICS OVERVIEW .

NOTE:

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

Fig 8: Aligning Drive Plate To Clutch Module

Courtesy of AUDI OF AMERICA, LLC

-- 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-.

-- Attach the transmission to the engine and tighten the bolts -3 through 11-. For the correct tightening specifications, refer to TIGHTENING SPECIFICATIONS .

Fig 9: Removing Starter Off Transmission And Leave It In Installation Position

Courtesy of AUDI OF AMERICA, LLC

-- Install the starter and tighten the bolt -1- from the engine side. Tightening specification TIGHTENING SPECIFICATIONS .

-- Next, use tightening torque TIGHTENING SPECIFICATIONS to tighten the bolt -2- from the transmission side.

-- Raise the transmission using the V.A.G 1383 A until dimension -a- is reached between the subframe and the body.

Fig 10: Raising Transmission

Courtesy of AUDI OF AMERICA, LLC

-a- = minimum 100 mm

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

Fig 11: Driveshaft Heat Shield - Tightening Specification

Courtesy of AUDI OF AMERICA, LLC

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

-- Tighten the push rod -1-. Tightening specification SELECTOR MECHANISM OVERVIEW .

Fig 12: Identifying Bolts For Selector Rod And Push Rod

Courtesy of AUDI OF AMERICA, LLC

-- Connect the connector -2- to the transmission range gear recognition switch -F208-.

-- Attach the connecting rod -3-. Tightening specification SELECTOR MECHANISM OVERVIEW .

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

Fig 13: Gearshift Lever Can Be Attached To The Gearshift Shaft In Only One Position

Courtesy of AUDI OF AMERICA, LLC

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 SELECTOR MECHANISM OVERVIEW .

-- Lift the transmission and tighten the tunnel crossmember bolts -arrows-. For the correct tightening specifications, refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Fig 14: Identifying Bolts & Tunnel Crossmember

Courtesy of AUDI OF AMERICA, LLC

-- Remove the V.A.G 1383 A and T40173.

-- Mount or install the driveshaft on the transmission. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE or DRIVESHAFT ATTACHED ON TRANSMISSION SIDE .

Fig 15: Holding Driveshaft Using T10172

Courtesy of AUDI OF AMERICA, LLC

Tightening Sequence - Clutch Module to the Drive Plate

-- Remove the T40169 and T40170.

-- Put in sixth gear; to do this, move the gearshift shaft -1-, push the gearshift lever -2- forward in direction of -arrow-.

Fig 16: Identifying Gearshift Assembly

Courtesy of AUDI OF AMERICA, LLC

-- Mount both front wheels.

Use the T10172 and T10172/5 to block the driveshaft to keep it from turning, too.

Fig 17: Holding Driveshaft Using T10172

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Turn both front wheels 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.

Fig 18: Locating Transmission Housing Check Hole
Courtesy of AUDI OF AMERICA, LLC

Tighten the clutch module to the drive plate as follows:

Fig 19: Identifying Clutch Module First Bolt Installation Location (2 Of 2)

Courtesy of AUDI OF AMERICA, LLC

Use new bolts.
Tightening specification CLUTCH MODULE OVERVIEW .
Tighten the bolts using the V.A.G 1332/14.

-- Install the first bolt -arrow- and tighten by hand (2 Nm).

-- Continue turning the clutch module/drive plate 180° via the front wheels.

-- Insert the second bolt and tighten it to the specification CLUTCH MODULE OVERVIEW .

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

Install in reverse order of removal paying attention to the following:

Fig 20: Pressing CV Joint Off Steering Gear And Slide It Up

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the universal joint on the steering gear. Refer to STEERING COLUMN, HANDLING AND TRANSPORTING .

-- Mount the right catalytic converter to the exhaust manifold. Refer to EXHAUST SYSTEM, EMISSION CONTROLS .

-- Install the left and right front muffler. Refer to EXHAUST SYSTEM, EMISSION CONTROLS .

-- Install the exhaust system so that it is free of tension. Refer to EXHAUST SYSTEM, EMISSION CONTROLS .

-- Install the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Install the coolant connection. Refer to CONNECTION DIAGRAM - COOLANT HOSES .

-- Install right coolant pipe. Refer to COOLANT PIPES .

-- Install the rear coolant pipe. Refer to COOLANT PIPES .

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

-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Tighten down both front wheels using tightening torque. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Install the noise insulation. Refer to NOISE INSULATION .

-- Observe measures 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 as a starting aid.