Installing gearbox in vehicles with V6 petrol engine: Audi A6 C6

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Renewed: if necessary

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• 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 grease for clutch plate splinesG 000 100 to the splines. Do not grease the guide sleeve.
• Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox.
• If the slave cylinder (1) is inserted at an angle, there is a danger that the plunger (arrow A) will be guided past the clutch release lever (3).
• Install front exhaust pipes and ensure stress-free alignment of exhaust system Engine, mechanics26.

📋 Procedure

1. 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 grease for clutch plate splinesG 000 100 to the splines. Do not grease the guide sleeve.
2. Check clutch release bearing for wear and renew if necessary .
3. Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.
4. Place intermediate plate on dowel sleeves at engine flange.
5. Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox.

6. Lightly lubricate surface where plunger and clutch release lever make contact (arrow B) using copper grease (commercially available).
7. Raise gearbox far enough to be able to install clutch slave cylinder with bracket for pipe/hose assembly.
8. Guide slave cylinder (1) into opening in gearbox housing, keeping it as straight as possible (without tilting plunger (arrow A)) and insert in recess (arrow B) on clutch release lever (3). [Note: If the slave cylinder (1) is inserted at an angle, there is a danger that the plunger (arrow A) will be guided past the clutch release lever (3).]
9. Secure clutch slave cylinder with new bolt (arrow). Tightening torque
10. ⚠ Press the clutch pedal carefully after installing the gearbox.If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further.The plunger of the slave cylinder is likely to have been guided past the clutch release lever.The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.For comparison: normal pedal force is approx. 115 N. — Insert guide pin of adapter T40058 so that the large diameter (arrow 1) faces engine. The smaller diameter (arrow 2) faces adapter.
11. When joining gearbox with engine, turn crankshaft backwards and forwards using adapter T40058 to help splines on input shaft engage in clutch plate.
12. Bolt gearbox onto engine. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.Do not use parts which have been degreased.Tolerance for tightening torques is ± 15%.]
13. Install gearbox selector lever and tighten nut (arrow).
14. Install push rod (1); to do so, tighten hexagon socket head bolt.
15. Secure connecting rod (2) for selector rod.
16. If removed earlier, fit gearbox support (2) to gearbox and tighten bolts (1) to specified torque .
17. Tighten bolts (arrows) for tunnel cross member. Tightening torques Exploded view - tunnel cross member, gearbox mounting and gearbox support
18. Loosen bolts (arrows) for torque reaction support.
19. Allow stop for torque reaction support to settle on rubber buffer for torque reaction support under its own weight and re-tighten bolts.
20. Bolt drive shafts to flange shafts Running gear, front-wheel drive and four-wheel drive40.
21. Install front exhaust pipes and ensure stress-free alignment of exhaust system Engine, mechanics26.
22. Fit cross member on subframe and install front cross member Running gear, front-wheel drive and four-wheel drive40.
23. Follow steps required after connecting battery Electrical system27. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.Do not use parts which have been degreased.Tolerance for tightening torques is ± 15%.]

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