Installing gearbox - vehicles with 8-cylinder MPI engine — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: gearbox oil
• Special tools named: T40058
• Renewed: self-locking nuts, oil seals
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• Before installing gearbox, check for correct positioning of dowel sleeves (A) at cylinder block. Install new dowel sleeves if necessary.
• Since access to the Lambda probe is restricted, it is not necessary to remove the catalytic converter with front silencer (right-side). The catalytic converter just has to be pulled off the studs so that the gasket can be renewed.
• When pushing the engine and gearbox together, ensure that no wiring or pipes etc. can become trapped.
• (Arrow) can be disregarded.
• When renewing gearbox, take off gearbox support from gearbox to be exchanged and fit to replacement gearbox.

📋 Procedure

1. Refer to repair instructions . [Note: 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.Hose connections and hoses for charge air system must be free from oil and grease before fitting.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, check for correct positioning of dowel sleeves (A) at cylinder block. Install new dowel sleeves if necessary.
3. Before installing gearbox, unscrew nuts (1, 2 and 3) securing catalytic converter with front silencer (right-side) to exhaust manifold. [Note: Since access to the Lambda probe is restricted, it is not necessary to remove the catalytic converter with front silencer (right-side). The catalytic converter just has to be pulled off the studs so that the gasket can be renewed.]
4. Renew gasket between exhaust manifold and catalytic converter with front silencer (right-side).
5. Re-fit catalytic converter with front silencer (right-side) on exhaust manifold and screw on nuts (1, 2 and 3) loosely.

6. If an intermediate plate was installed between engine and gearbox, reinstall plate in same position.
7. 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.
8. When pushing the engine and gearbox together, ensure that no wiring or pipes etc. can become trapped.
9. 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 ±15%.]
10. Renew gasket between exhaust manifold and catalytic converter with front silencer (left-side).
11. Install catalytic converter with front silencer on both sides 26.
12. Insert guide pin of adapter T40058 so that the large diameter (arrow 1) faces engine. The smaller diameter (arrow 2) faces adapter.
13. Counter-hold crankshaft using adapter T40058 to secure torque converter bolts. [Note: (Arrow) can be disregarded.]
14. Use new genuine bolts to secure the torque converter to the drive plate.
15. Screw in 6 bolts (arrow) for torque converter through opening for removed starter, and tighten lightly (turning crankshaft 1/3 turn each time).
16. Then tighten torque converter bolts to torque (turning the crankshaft 1/3 turn each time).
17. Install starter 27.
18. Connect ATF coolant hoses going to ATF cooler and remove hose clamps up to Ø 25 mm3094.
19. Attach electrical connector to gearbox by fitting fastener cap and turning clockwise in opposite direction of (arrow).
20. Attach engine speed sender G28 to gearbox (arrow) and tighten 10.
21. Install rear gearbox supports with gearbox mountings .
22. Install front gearbox supports with gearbox mountings . [Note: When renewing gearbox, take off gearbox support from gearbox to be exchanged and fit to replacement gearbox.]
23. Install subframe 40.
24. Install bolt (arrow) securing support mounting to engine 10.
25. Bolt propshaft onto gearbox Rear final drive 01R39 or Rear final drive 0AR39.
26. Bolt drive shafts to flange shafts 40.
27. Electrical connections and routing .
28. Adjust selector lever cable .
29. Check gear oil level in gearbox .
30. Install exhaust system so it is free of stress 26.
31. Follow the steps required after connecting the battery 27.
32. Fill up with coolant 19.
33. Check ATF level .
34. Perform wheel alignment 44

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• 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 lower window trim · 1 torque figures
• Repair instructions
• Connecting up vehicle diagnostic, testing and information system VAS 5051 and selecting functions
• Removing and installing camshaft toothed belt
• Checking lambda probe heating for lambda probes upstream or downstream of catalytic converter