Installing gearbox - Audi A4, A5 with 3.2 ltr. FSI engine — AUDI

🧭 Before you start

Fits: Audi A5 Cabriolet (8F), Audi A5 (8T, 2007–2016), Audi A4 B8 (8K, 2007–2015)

• Opens: gearbox oil
• Renewed: needle bearing in drive plate

Don't miss

• There is only one inspection hole at the periphery; turn the clutch module accordingly.
• The next step is only required if a drive plate with locating pins (2) is installed.
• The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant.

🔩 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. Position gearbox on gearbox support T40173 and secure with tensioning strap (1), as shown in illustration.
2. Check input shaft for scoring around bearing in drive plate (arrow). Renew needle bearing in drive plate if necessary 13Cylinder block (gearbox end); Renewing needle bearing in drive plate.
3. Check that dowel sleeves (A) for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.
4. If removed previously, install clutch module Servicing manual gearbox30Clutch; Removing and installing clutch module.
5. The following preparations must be made before joining the engine and gearbox:

6. Insert assembly aid T40169 between gearbox housing and clutch module from below, as shown in illustration. [Note: There is only one inspection hole at the periphery; turn the clutch module accordingly.]
7. Insert pin of assembly aid into hole on gearbox housing.
8. Insert transportation lock T40170 into gearbox housing from below and clamp onto flange shaft (1).
9. Raise gearbox just far enough to be able to insert clutch slave cylinder (1).
10. Tighten bolt (2). Tightening torque [Note: The next step is only required if a drive plate with locating pins (2) is installed.]
11. In addition, align drive plate with clutch module so that locating pins (2) (if provided) on drive plate can engage in large holes (1) on clutch module.
12. ⚠ An incorrectly installed clutch causes functional problems.If the locating pins on the drive plate (2) are not located in the holes on the clutch module (1), this will lead to considerable functional problems of the clutch. — Join gearbox to engine and tighten bolts (3 ... 11); tightening torques .
13. Fit starter and tighten bolts (1) and (4). Tightening torque
14. Raise gearbox using engine and gearbox jackV.A.G 1383 A initially only until dimension (a) is reached between tunnel cross member and body.
15. Secure push rod (1).
16. Secure connecting rod (3). Tightening torque
17. Plug in electrical connector (2) at gear detector switch F208.
18. Install gearbox selector lever (2) as follows:
19. Secure gearbox selector lever (2). Tightening torque
20. Release spindle10 - 222 A /11.
21. Raise gearbox further and tighten bolts (arrows) for tunnel cross member. Tightening torques
22. Remove engine and gearbox jackV.A.G 1383 A and gearbox support T40173.
23. Secure drive shafts (left and right) to flange shafts of gearbox Running gear, axles, steering40Drive shaft; Exploded view - drive shaft.
24. Install heat shield for drive shaft .
25. Install propshaft Rear final drive39Propshaft; Exploded view - propshaft.
26. If originally fitted, install subframe shield (left and right) Running gear, axles, steering40Subframe; Exploded view - subframe.
27. Remove assembly aid T40169 and transportation lock T40170.
28. Engage 6th gear by pulling out selector shaft (1) and shifting gearbox selector lever (2) forwards in direction of (arrow). [Note: The following step is essential to ensure that the clutch module makes even and proper contact on the drive plate and does not cant.]
29. Turn both front wheels together in one direction until the clutch module has turned through one complete revolution (360°).
30. Secure clutch module to drive plate as follows:
31. Install first bolt (arrow) and tighten hand-tight (2 Nm). — 2 Nm (1.5 lb-ft)
32. Turn both front wheels so that clutch module turns 180° further in direction of engine rotation.
33. Then screw in and tighten second bolt. Tightening torque
34. Now install remaining bolts all round, and tighten immediately (also tighten the first bolt installed). Tightening torque
35. Secure universal joint to steering rack Running gear, axles, steering48Steering column; Exploded view - steering column.
36. If fitted, install heat shield for propshaft (A) and tighten bolts (arrows) to 25 Nm. — 25 Nm (18 lb-ft)
37. Install catalytic converter (right-side) 26Emission control system; Removing and installing catalytic converter.
38. Install front silencers (left and right) 26Exhaust pipes/silencers; Removing and installing front silencer.
39. Perform stress-free alignment of exhaust system 26Exhaust pipes/silencers; Stress-free alignment of exhaust system.
40. Install subframe cross brace Running gear, axles, steering40Subframe; Exploded view - subframe.
41. Check gear oil level in gearbox .
42. Install noise insulation General body repairs, exterior66Noise insulation; Exploded view - noise insulation.
43. Install plenum chamber partition panel General body repairs, exterior50Bulkhead; Exploded view - plenum chamber partition panel.
44. Observe measures required after connecting battery Electrical system27Battery; Disconnecting and connecting battery.

Other AUDI procedures

• Removing and installing toothed belt · 56 torque figures
• Removing engine · 41 torque figures
• Removing camshaft timing chain from camshafts · 38 torque figures
• Installing engine · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing windscreen and undamaged side, rear window
• Removing and installing over-centre spring, pedal cluster removed
• Checking vacuum reservoir and vacuum hoses
• Checking fuel pump non-return valve, engine code BGU
• Removing and installing fuel tank, front-wheel drive, engine codes BJB, BLS, BSU, BDJ, BST, BMM