Gearbox removal & installation: Audi 4.2 (BNS)

🧭 Before you start

Fits: Audi A4 Cabriolet B6/B7 (8H), Audi A4 B6/B7 (8E)

• Opens: coolant
• Special tools named: VAS 6131/10

Don't miss

• If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring.New SAC pressure plates are already pre-set accordingly, and do not have to be reset.
• 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 greaseG 000 100 to the splines. Do not lubricate guide sleeve.
• Check clutch release bearing for wear and make sure that plastic ring is securely seated 30.
• The threaded holes in the flange shaft for the propshaft on the gearbox must be cleaned of remaining locking fluid with a thread tap before assembling.
• The mounting points for engine (front) and tunnel cross member remain unchanged.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. When fitting a new clutch plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. If this is not done, the pressure plate will operate with reduced clamping force, causing clutch slip 30. [Note: If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring.New SAC pressure plates are already pre-set accordingly, and do not have to be reset.]
2. 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 greaseG 000 100 to the splines. Do not lubricate guide sleeve.
3. Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch).
4. Check clutch release bearing for wear and make sure that plastic ring is securely seated 30.
5. Install engine supports (left and right) .

6. Check whether dowel sleeves (A) for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves.
7. Press intermediate plate between engine and gearbox onto dowel sleeves.
8. Bolt gearbox to engine. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite.Do not use degreased parts.Tolerance for tightening torques ± 15 %.]
9. Install exhaust manifolds: left-side , right-side .
10. Install front exhaust pipes with starter and main catalytic converter: left-side , right-side .
11. The threaded holes in the flange shaft for the propshaft on the gearbox must be cleaned of remaining locking fluid with a thread tap before assembling.
12. Screw down spindles of support elements on left side of engine/gearbox assembly.
13. Unscrew both base plates for support elements (left-side) at scissor-type assembly platformVAS 6131 A.
14. Screw down spindles of support elements on right side of engine/gearbox assembly.
15. Unscrew both base plates for support elements (right-side) at scissor-type assembly platformVAS 6131 A. [Note: The mounting points for engine (front) and tunnel cross member remain unchanged.]
16. Set up scissor-type assembly platformVAS 6131 A with support set for AudiVAS 6131/10 as follows:
17. Fit subframe onto the two support elements VAS 6131/10-8.
18. Screw up the spindles for support elements on both sides.
19. Tighten base plates for support elements to 20 Nm on scissor-type assembly platformVAS 6131 A. — 20 Nm (15 lb-ft)
20. Carefully guide engine/gearbox assembly together with subframe into the body from below using scissor-type assembly platformVAS 6131 A.
21. Raise the engine/gearbox assembly using scissor-type assembly platformVAS 6131 A until the distance (a) is reached.
22. Secure coolant hose (arrow) to rear coolant pipe (hose leads to heat exchanger for heater).
23. Secure slave cylinder with new bolt (arrow); procedure 30.
24. Install selector mechanism 34.
25. Raise subframe via scissor-type assembly platformVAS 6131 A until subframe makes contact with body.
26. Adjust the subframe, consoles for engine mountings and tunnel cross member according to the markings made on the longitudinal members during removal.
27. Only tighten bolts for subframe, consoles for engine mountings and tunnel cross member to the specified torque (do not turn further); tighten bolts to final setting only after performing wheel alignment check 40.
28. ⚠ The vehicle must not be driven at this stage. — Install drive shafts 40.
29. Install guide links, track control links and suspension struts 40.
30. Install propshaft Rear final drive 01R39.
31. Align exhaust system so it is free of stress .
32. Install hydraulic pressure line for power steering 48.
33. Secure fuel supply line to fuel rail 20.
34. Install refrigerant lines 87.
35. Install anti-roll bar 40.
36. Install torque reaction support .
37. Install lock carrier with attachments 50.
38. Install bumper cover (front) 63.
39. Electrical connections and routing .
40. Observe notes on procedures required after connecting battery 27.
41. ⚠ Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units. — Install and adjust wiper arms 92.
42. Fill up with engine oil and check oil level 803 or 805.
43. Before starting engine, top up hydraulic fluid in power steering reservoir 48. [Note: The power steering pump must not be run when dry.]
44. Fill cooling system . [Note: Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.Contaminated or dirty coolant must not be used again.]
45. Charge the refrigerant system Air conditioner system - with refrigerant R134a.
46. Adjust subframe and the two consoles for engine mountings 40.
47. Fit front wheels and perform wheel alignment 44.
48. ⚠ Tighten bolts for subframe to final setting after performing wheel alignment check. — Check headlight adjustment 803 or 805. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite.Do not use degreased parts.Tolerance for tightening torques ± 15 %.]

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