Installing gearbox on vehicles with V8 4.2 ltr. FSI engine — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: gearbox oil
• Renewed: self-locking nuts, oil seals
• Also covered elsewhere: Electronic parts catalogue

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• Before installing gearbox, you must ensure that the torque converter is properly fitted in the gearbox.
• When pushing the engine and gearbox together, ensure that no wiring or pipes etc. can become trapped.
• (Arrow) can be disregarded.

📋 Procedure

1. Observe all the repair instructions . [Note: Clean ATF pipes and ATF cooler before installing exchange gearbox .Renew self-locking nuts and bolts when performing assembly work.Renew oil seals and gaskets, and bolts which are tightened by turning through a specified angle.Re-attach heat shield sleeves at the same locations when re-installing.Secure all hose connections with the correct hose clips (as original equipment); refer to Electronic parts catalogue.Re-attach all cable ties at the same locations when re-installing.]
2. Before installing gearbox, you must ensure that the torque converter is properly fitted in the gearbox.
3. ⚠ If the torque converter is not fitted correctly, the torque converter drive lugs or the ATF pump will be irreparably damaged when the gearbox is joined to the engine. — Before installing gearbox, check for correct positioning of dowel sleeves (A) at cylinder block. Install new dowel sleeves if necessary.
4. If an intermediate plate was installed between engine and gearbox, reinstall plate in same position.
5. Before joining engine and gearbox, turn torque converter and drive plate (on engine) until one hole and one tapped hole are in line with the opening for the removed starter.

6. When pushing the engine and gearbox together, ensure that no wiring or pipes etc. can become trapped.
7. ⚠ Before and while you are tightening the bolts on the engine/gearbox flange keep checking that the torque converter can still be rotated behind the drive plate. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened. — Bolt gearbox onto engine.
8. Raise the engine/gearbox assembly further.
9. Secure gearbox cross member. [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 ±15%.]
10. Insert guide pin of adapter T40058 so that the large diameter (arrow 1) faces engine. The smaller diameter (arrow 2) faces adapter.
11. Counter-hold crankshaft using adapter T40058 to secure torque converter bolts. [Note: (Arrow) can be disregarded.]
12. Use new bolts (genuine Audi parts) to secure torque converter to drive plate Electronic parts catalogue.
13. Screw in 3 bolts (arrow) for torque converter through opening for removed starter, and tighten lightly (turning crankshaft 1/3 turn each time).
14. Then tighten torque converter bolts to torque (turning the crankshaft 1/3 turn each time).
15. Install tunnel cross member.
16. Install coolant pipe (bottom left) Engine, mechanics19.
17. Install ATF pipes .
18. Adjust selector lever cable .
19. Install front gearbox supports with gearbox mountings .
20. Bolt propshaft onto gearbox Rear final drive 01R39 or Rear final drive 0AR39.
21. Install exhaust system so it is free of stress Engine, mechanics26.
22. Install front cross piece General body repairs, exterior50.
23. Install starter Electrical system27.
24. Install engine support with engine mounting (right-side) Engine, mechanics10.
25. Install engine cross member Engine, mechanics10.
26. Install subframe Running gear, front-wheel drive and four-wheel drive40.
27. Install anti-roll bar Running gear, front-wheel drive and four-wheel drive40.
28. Bolt drive shafts to gearbox flange shafts Running gear, front-wheel drive and four-wheel drive40.
29. Install cross member on subframe Running gear, front-wheel drive and four-wheel drive40.
30. Install ATF cooler and ATF pipes .
31. Install body brace Running gear, front-wheel drive and four-wheel drive40.
32. Electrical connections and routing .
33. Check gear oil level in front final drive .
34. Check gear oil level in transfer box .
35. Follow steps required after connecting battery Electrical system27.
36. Check ATF level in planetary gearbox .

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