Transmission, Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Assembly Aid T40169
Transportation Lock T40170
Gearbox Support T40173
Spindles 10 - 222 A /11
Ring Spanner Insert AF16 V.A.G 1332/14
Hose Clamps Up to 25 mm in Dia. 3094

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.

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.

Transmission installation tightening specifications TRANSMISSION, INSTALLING .

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

Fig 1: Positioning V.A.G 1383 A And T40173 Under Transmission And Secure It With Tensioning Strap -1-

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-- 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 the appropriate service information .

Fig 2: 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 3: Identifying Transmission / Engine Bolts

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

-- Installing the clutch module if necessary. Refer to Removal and Installation .

Fig 4: Identifying Flywheel Components, Remove/Install

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-- 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

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-- 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 assembly device 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

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-- Raise the transmission straight up until the clutch slave cylinder -1- can be inserted.

Fig 7: Raising Transmission Straight Up Until Clutch Slave Cylinder Can Be Inserted

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-- Tighten bolt -2-. Tightening specification -item 17- CLUTCH HYDRAULICS OVERVIEW .

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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-- 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-.

-- Connect the transmission to the engine and tighten -3.... 11- the bolts. Tightening specifications TRANSMISSION, INSTALLING .

Fig 9: Identifying Transmission / Engine Bolts

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

Fig 10: Inserting Starter And Tighten Bolt

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-- Install the spacer sleeve -2- between the starter and transmission, push the bolt -1- through and tighten.

-- Tighten the starter bolts -1 and 3-. Tightening specifications TRANSMISSION, INSTALLING .

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

Fig 11: Lowering Transmission

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-a- = minimum 80 mm

-- Attach the push rod -1- -item 27- 27.

Fig 12: Identifying Bolts For Selector Rod And Push Rod

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-- Attach the connecting rod -3-. Tightening specification -item 25- 25.

-- Connect the connector -2- to the transmission range gear recognition switch -F208- or the gear recognition sensor -G604-.

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-).

-- Tighten the selector lever. Tightening specification -item 18- 18.

-- Connect the connector to the transmission neutral position sensor -G701- -1-.

Fig 14: Identifying Connector To Transmission Neutral Position Sensor

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-- Loosen the 10 - 222 A /11.

Fig 15: Loosening 10 - 222 A

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-- Lift the transmission further and tighten the bolts -arrows- on the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Fig 16: Identifying Bolts & Tunnel Crossmember

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

-- Attach the left and right drive axles to the transmission flange shafts. Refer to OVERVIEW - DRIVE AXLE .

Fig 17: Identifying Left And Right Drive Axles

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-- Install the driveshaft heat shield. Refer to Fig 27.

Fig 18: Drive Axle Heat Shield - Tightening Specification

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

-- Secure the driveshaft on the transmission. Refer to Removal and Installation (0BC) or Removal and Installation (0BD) .

Fig 19: Counterholding Driveshaft Using T10172 And T10172/5

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Block the driveshaft. To do this, place the T10172 and T10172/5 on the driveshaft bolts on the transmission or the rear final drive.

Tightening Sequence - Clutch Module to the Drive Plate

Fig 20: Identifying Gearshift Assembly

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-- Remove the T40169 and 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 21: 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 22: Identifying Clutch Module First Bolt Installation Location

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Use new bolts.
Tightening specification -item 3- CLUTCH MODULE OVERVIEW .
Tighten the bolts using the V.A.G 1332/14.

-- 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 -item 3- CLUTCH MODULE OVERVIEW .

-- Tighten the remaining two bolts. Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Install in reverse order of removal. Note the following:

Fig 23: Identifying Transmission Heat Shield

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

-- Install the exhaust system so that it is free of tension. Refer to the appropriate service information .

Vehicles with Transmission Fluid Heater

Fig 24: Identifying Coolant Hoses & 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 3094.

-- Fill with coolant. Refer to the appropriate service information .

All Vehicles

Fig 25: Pressing CV Joint Off Steering Gear And Slide It Up

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-- Attach the steering intermediate shaft to the steering gear. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

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

Fig 26: Identifying Subframe Crossbrace & Bolts

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

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

-- Complete the steps required after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

Danger of causing damage to the control modules due to the excess voltage.

Do not use a charger to jump start!

Tightening Specifications

NOTE:

The tightening specifications apply only 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 any ungreased parts.

Tightening specification tolerance +/- 15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65
Except for the following:

Fig 27: Drive Axle Heat Shield - Tightening Specification

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-- Tighten the heat shield bolts -arrows- to 23 Nm.

Securing the Engine to the Manual Transmission

Fig 28: Identifying Transmission / Engine Bolts

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Item

Bolt

1 ¹⁾

M10x50 ²⁾

2 ³⁾ , 7

M12 x 100 ⁴⁾⁵⁾

30 + 90°

3 ⁶⁾ , 6

M12 x 75 ⁴⁾⁵⁾

30 + 90°

4, 5 ⁶⁾

M12 x 120 ⁴⁾⁵⁾

30 + 90°

8 ••• 10

M10 x 75 ⁴⁾⁵⁾

15 + 90°

M12 x 50 ⁴⁾⁵⁾

30 + 90°

Alignment sleeve for centering

¹⁾ Mount the auxiliary adapter.
²⁾ Bolt strength rating 10.9. There is no limit to the number of times steel bolts may be used.
³⁾ Also secures that starter; with an additional spacer sleeve between the starter and the transmission.
⁴⁾ Audi A4 through VIN 8K-9-066499 and Audi A5 through VIN 8T-9-007999: Replace the aluminum bolts.
⁵⁾ Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: Aluminum bolts can be used twice; refer to TRANSMISSION, INSTALLING .
⁶⁾ Also attaches the bracket for the electric wire.

⁽¹⁾	To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a /₂ drive, which is inserted in to the vise, as illustrated.

Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.

Fig 29: Identifying Bolts Marked With An "X" May Not Be Used Again
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Bolts marked with an "X" may not be used again.
Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.
Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.