Installing gearbox, four-wheel drive — AUDI

🧭 Before you start

Fits: VW Transporter T5 (7H), VW Transporter T5 (7J), VW Transporter T6 (7E), VW Transporter T6 (7F)

• Opens: clutch fluid
• Renewed: self-locking bolts, oil seal

Don't miss

• Always renew self-locking bolts and nuts.
• Ensure that intermediate plate is correctly seated on engine.
• Do not yet screw in engine/gearbox connecting bolt (arrow A).
• Do not remove support bracket 10 - 222 A until all bolts of left subframe mounting are tightened to specified torque. — Push on connector for tachograph drive, if fitted.
• Pendulum support bolts always must be renewed.

📋 Procedure

1. ⚠ Please observe the following points during all installation work, in particular in the engine compartment, due to the space limitations:Route lines of all kinds and electrical cables so as to re-establish the original wiring.Make sure there is adequate clearance from all moving or hot parts. — Renew circlip (arrow A) and oil seal (arrow B) on left stub shaft.
2. Renew circlip (arrow A) and oil seal (arrow B) on right stub shaft.
3. Grease splines of stub shafts on left and right with greaseElectronic Parts Catalogue.
4. Clean splines of input shaft and lightly grease them with greaseElectronic Parts Catalogue.
5. Always renew self-locking bolts and nuts.

6. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.
7. Ensure that intermediate plate is correctly seated on engine.
8. Align arms of gearbox support according to holes in adjustment plate.
9. Place gearbox on gearbox jack.
10. Align adjustment plate and gearbox parallel to one another.
11. Secure support(arrow) to gearbox with a bolt M10 x 20.
12. Position engine and gearbox jackV.A.G 1383/A under vehicle.
13. Raise gearbox and guide reversing light switch (arrow) past left longitudinal member.
14. Guide output flange of bevel box past steering rack when raising.
15. Align gearbox to engine and join.
16. Screw in engine/gearbox connecting bolt (arrow B) behind bevel box (1). [Note: Do not yet screw in engine/gearbox connecting bolt (arrow A).]
17. Screw in upper (arrows) and lower (A) engine/gearbox connecting bolts and tighten them.
18. After gearbox has been bolted to engine, remove gearbox support3282 from gearbox.
19. Align engine and gearbox in installation position. To do this, tighten threaded spindle of adapter10-222 A/16 and spindle of support bracket10-222 A until gearbox mounting contacts left longitudinal member.
20. When raising engine and gearbox, guide front torque reaction support with support mounting past body.
21. Screw in new hexagon bolts (arrows) for left assembly mounting and tighten it.
22. ⚠ Do not remove support bracket 10 - 222 A until all bolts of left subframe mounting are tightened to specified torque. — Push on connector for tachograph drive, if fitted.
23. Attach bracket (A) for power assisted steering lines to gearbox (arrow).
24. Renew oil seal on slave cylinder line connection.
25. Push pipe/hose assembly (A) with bleeder onto slave cylinder to stop and press clip down (arrow).
26. Remove hose clamp to 25 mm3094.
27. Bleed clutch mechanism .
28. Install starter (3)Electrical system27Removing and installing starter.
29. Attach connector for reversing light (2).
30. Connect earth strap (1) to lower starter bolt.
31. Bolt bracket for wiring harness to upper securing bolt for starter.
32. Screw in engine/gearbox connecting bolt (arrow B) in figure N34-10410 and tighten it. [Note: Pendulum support bolts always must be renewed.]
33. Install rear torque reaction support of engine and tighten bolts (qty. 4) 10Assembly mountings.
34. Bolt bevel box carrier (A) to rear torque reaction support (B) and to bevel box (bolts (1) and (2)), observing tightening sequence.
35. Press left and right drive shafts onto stub shafts Running gear, axles, steering40Drive shafts; Removing and installing drive shaft.
36. Install subframe Running gear, axles, steering40Assembly overview - subframe; Removing and installing subframe.
37. Install front propshaft tube Propshaft and rear final drive39Final drive, rear differential.
38. Install heat shield (arrow) on bevel box.
39. Assemble exhaust system and attach exhaust system bracket to subframe 26Emission control.
40. If fitted, attach noise insulation for left and right drive shafts to wheel housing.
41. Pull back catch of cable support bracket (1)(arrow A) and insert into gearbox (2)(arrow B).
42. Spread a small quantity of greaseElectronic Parts Catalogue on pins of gearbox selector lever (4) and of relay lever (3).
43. Press gear selector cable (5) onto gearbox selector lever (4) and gate change cable (2) onto relay lever (3).
44. Check that cables are firmly seated on gearbox selector lever and relay lever.
45. Check function of selector mechanism and adjust if necessary or .
46. Attach noise insulation (4), if present, to front plenum chamber.
47. Install bracket for vacuum reservoir (3) on plenum chamber.
48. Push connector onto bracket for vacuum reservoir (3).
49. Bolt connecting hose with intake connecting pipe (2) to intake manifold and install it to charge air cooler Power unit21Charge air system.
50. Bolt on coolant expansion tank (1).
51. Then attach left and right plenum chamber bulkhead panels to plenum chamber General body repairs, interior50Assembly overview - plenum chamber bulkhead.
52. Install plenum chamber cover General body repairs, exterior66Mouldings and trims.
53. Connect battery.
54. Check gear oil in gearbox .
55. Check gear oil in bevel box .
56. If present, install noise insulation (A) from gearbox (arrows).
57. Install any noise insulation General body repairs, exterior50Noise insulation.
58. Install wheels Running gear, axles, steering44Fitting wheel and tyre.

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• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing and installing lower rear lid trim, Multivan
• Removing and installing carrier unit
• Removing undamaged sliding window for sliding door
• Removing and installing clutch master cylinder with mounting bracket removed
• Removing and installing rear bonded rubber bush for rear final drive