Installing gearbox - vehicles with 8-cyl. FSI engine (Audi RS 4) — AUDI

🧭 Before you start

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

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

Don't miss

• Always renew self-locking bolts and nuts.
• 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 and brackets off to one side so that they are not 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).
• The bottom bolts are fitted at a later stage.

📋 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 securing bolts between engine and gearbox that are accessible from above.
18. Install starter and tighten securing bolts (1) and (3)Electrical system27. [Note: The bottom bolts are fitted at a later stage.]
19. Tighten bolts (2) and (4) for heat shield.
20. Secure engine speed sender G28 with heat shield on left side of gearbox (arrow).
21. Fit gearbox selector lever (2) and tighten nut (1). Tightening torque
22. Bolt push rod (1) onto gearbox. Tightening torque
23. Secure connecting rod (2). Tightening torque
24. Attach electrical connector (arrow) for reversing light switch F4 on gearbox (right side).
25. 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.
26. Bolt propshaft onto gearbox (arrows)Rear final drive 01R39 or Rear final drive 0AR39/Rear final drive 08V39.
27. Bolt on heat shield for propshaft (arrows).
28. Bolt tunnel cross member onto gearbox mounting (arrows). Tightening torque
29. Bolt bracket for front exhaust pipe (right-side) to gearbox (arrows).
30. Bolt bracket for front exhaust pipe (left-side) to gearbox (arrows).
31. Install front exhaust pipes with catalytic converters Engine, mechanics26.
32. Bolt drive shafts to flange shafts Running gear, front-wheel drive and four-wheel drive40.
33. Install heat shields (arrow) for drive shafts (left and right).
34. Apply lifting column of engine and gearbox jackV.A.G 1383 A to tunnel cross member from below (with gearbox support T10337 attached).
35. Push tunnel cross member upwards using engine and gearbox jackV.A.G 1383 A.
36. Renew bolts (3 … 4).
37. Bolt on tunnel cross member hand-tight.
38. Install clamps (1) and (2) for exhaust system.
39. Install exhaust system so it is free of stress Engine, mechanics26.
40. First remove front bolts (2) and (3) on subframe (left and right). Then remove bolts (1).
41. Lower subframe at the front.
42. Tighten three bottom engine/gearbox securing bolts (arrows).
43. Renew bolts for subframe.
44. Tighten new bolts for subframe, consoles for engine mountings and tunnel cross member only to initial torque setting, do not yet turn further (wait until wheel alignment has been carried out).
45. ⚠ The vehicle must not be driven in this condition. — After completing all assembly work, perform wheel alignment Running gear, front-wheel drive and four-wheel drive44.
46. Locate subframe on body before tightening bolts using locating pins3393.
47. Secure subframe Running gear, front-wheel drive and four-wheel drive40.
48. Secure tunnel cross member .
49. Tighten nuts (1) for engine mountings Engine, mechanics10.
50. Check selector mechanism setting and adjust if necessary .
51. Check gear oil level in gearbox .
52. Follow steps required after connecting battery Electrical system27.
53. If necessary, check wheel alignment Running gear, front-wheel drive and four-wheel drive44. [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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