Installing gearbox - vehicles with 3.0 ltr. TDI engine: Audi A4 Cabriolet B6/B7 / A4 B6/B7

🧭 Before you start

Clean threads, renew self-locking fasteners, prepare splines and release bearing and check the dowel sleeves. Raise the gearbox, guide the slave cylinder straight into the release lever recess and secure with a new bolt. Fit and tighten the engine/gearbox bolts, selector lever, push rod, connecting rod and cross member, then the drive shafts, torque reaction support, anti-roll bar, starter, connectors and propshaft. Refit heat shields (23 Nm where specified), exhaust and noise insulation, check gear oil level and selector setting, and complete the steps after reconnecting the battery.

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

• Opens: gearbox oil
• Renewed: self-locking bolts, if necessary

Don't miss

• Insert the slave cylinder straight; an angled plunger can bypass the release lever.
• If the clutch pedal meets unusual resistance, stop: the slave cylinder is destroyed above about 300 N.
• Clean all threads for self-locking bolts with a tap and always renew self-locking bolts and nuts.
• Grease the input splines very thinly and never grease the guide sleeve.
• Torques apply to lightly oiled fasteners; never use graphite lubricant or degreased parts.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 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. Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.
2. Always renew self-locking bolts and nuts.
3. 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.
4. Check clutch release bearing for wear and renew if necessary .
5. If plastic ring (arrows) has come loose, service release bearing as required .

6. Grease release bearing .
7. Check that dowel sleeves for centralising engine/gearbox (arrows) are in cylinder block, install if necessary.
8. If fitted, place intermediate plate on dowel sleeves at engine flange.
9. Before installing gearbox, tie electrical wiring and brackets off to one side so that they are not trapped between the engine and the gearbox.
10. Place gearbox on gearbox jack.
11. Lightly lubricate surface where plunger and clutch release lever make contact (arrow B) using copper grease (commercially available).
12. Raise gearbox far enough to be able to install clutch slave cylinder with bracket for pipe/hose assembly.
13. 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).
14. Use new hexagon socket head bolt (2) to secure to gearbox. [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).]
15. Tighten new bolt (arrow) to specified torque .
16. ⚠ 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 gearbox, making sure there is sufficient clearance to drive shafts.
17. Tighten engine/gearbox securing bolts (3) and (6 … 10).
18. Fit gearbox selector lever (2) and tighten nut (1). Tightening torque
19. Bolt push rod (1) onto gearbox. Tightening torque
20. Secure connecting rod (2). Tightening torque
21. Secure tunnel cross member on gearbox mounting (4). Tightening torque
22. Lift gearbox with engine and gearbox jackV.A.G 1383 A.
23. Screw in bolts (2) and new bolts (3) hand-tight.
24. Tighten bolts (3). Tightening torques
25. Tighten bolts (2). Tightening torques
26. Carefully lower engine and gearbox jackV.A.G 1383 A and move it aside.
27. Bolt drive shafts (1) to flange shafts Running gear, front-wheel drive and four-wheel drive40.
28. Install stop for torque reaction support and torque reaction support.
29. Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and tighten nuts (arrows)Engine, mechanics10.
30. Secure anti-roll bar to subframe at mountings (1) and (2)Running gear, front-wheel drive and four-wheel drive40.
31. Install starter Electrical system27.
32. Attach connector (arrow) for reversing light switch F4 on right side of gearbox.
33. Plug in electrical connector (arrow) for engine speed sender G28.
34. It is important to clean the threaded holes for the propshaft bolts to remove any remaining locking fluid. The residue can be removed using a tap.
35. Bolt propshaft onto gearbox (arrows)Rear final drive 01R39 or Rear final drive 0AR39/Rear final drive 08V39.
36. If fitted, install heat shield for propshaft (arrows).
37. Install exhaust system so it is free of stress Engine, mechanics26.
38. Check gear oil level in gearbox .
39. Install heat shield for drive shaft (arrow).
40. Install noise insulation (1) for drive shaft (left-side) in wheel housing.
41. Install bracket for noise insulation.
42. Install noise insulation (front and rear) with fasteners (1 … 3).
43. Remove support bracket10 - 222 A.
44. Tighten engine/gearbox securing bolts (4) and (5).
45. Install coolant expansion tank and air duct in engine compartment.
46. Install engine cover panel.
47. Check selector mechanism setting and adjust if necessary .
48. 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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