Audi A6 Typ 4G: Transmission, Installing

Special tools and workshop equipment required

• Torque Wrench 1332 Insert - Ring Wrench - 16mm -VAG1332/14-
• Clutch Module Assembly Aid -T40169-
• Clutch Module Transportation Lock -T40170-

Transmission installation tightening specifications, refer to → Chapter "Transmission Tightening Specifications"

Procedure

  Note

• Replace the bolts that were tightened with an additional turn.
• Replace self-locking nuts and bolts and seals, gaskets and o-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory, refer to the Parts Catalog.
• To secure the air guide hoses on their connections, spray the clamps used previously with rust remover before installing.
• When installing, bring all cable ties back to same positions.

Check that the bleeder hose is installed correctly for vehicles with 6-cylinder engines:

• The elbow of the bleeder hose -2- must be pressed onto the connection -1-.

- Press on the loose elbow until it audibly engages.

- Check that the base for both of the clamps -3- are correctly seated on the housing ribs -4-:

• The distance -a- from the rear clamp base to the housing flange must be 130 mm.

Check that the bleed pipe is installed correctly for vehicles with 8-cylinder engines:

• The elbow of the bleeder pipe -2- must be pressed onto the connection -1-.

- Press on the loose elbow until it audibly engages.

• The bleed pipe retaining pin must connect in the bolt head -5-.
• The bolt -4- must be tightened to 10 Nm.
• The ATF breather pipe -3- must remain open.

All vehicles:

- Clean the ATF pipe and the ATF cooler after replacing the transmission or after repairing the transmission.

- Always clean the threaded holes for the engine/transmission bolts in the cylinder block before assembling the transmission using a thread cutter.

  Caution

Danger of leaks in the ATF pan.

The Gearbox Support -T40173- must not be set on the ATF pan.

- Mount the transmission onto the Gearbox Support -T40173- and secure it using the tension strap -1- as illustrated.

- The following preparations must be made before connecting the engine and transmission:

- Insert the Clutch Module Assembly Aid -T40169- in the transmission housing and the flywheel from below as shown in the illustration.

• The assembly tool must engage in the semi-circular opening -1- and into the check hole -2-.

  Note

There is only 1 inspection opening on the circumference. Rotate the flywheel as needed.

- Install the bolts from the assembly device into the holes on the transmission housing.

- Insert the Clutch Module Transportation Lock -T40170- in the transmission housing from below and secure it on the flange shaft -1-.

- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary.

- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

- Connect the transmission to the engine and then tighten the engine/transmission connecting bolts -6- and -7-.

- Install the tunnel crossmember, refer to → Chapter "Overview - Subframe Mount".

  Note

The illustration id shown without the Engine and Gearbox Jack -VAS6931-.

- Lower the Engine and Gearbox Jack -VAS6931- with the Gearbox Support -T40173- and set aside.

- Tighten then engine bolts to the transmission accessible from underneath.

- Remove the Clutch Module Transportation Lock -T40170- and the Clutch Module Assembly Aid -T40169-.

  Note

The following step is necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.

- Push the flywheel slightly against the drive plate -3--arrow--2- using a pry bar -1-.

  Note

Use the Torque Wrench 1331 Insert - Open Jaw - 13mm -VAG1332/14- to tighten the bolts.

- Tighten the flywheel to the drive plate as follows:

- Install the first bolt -arrow- and tighten by hand (2 Nm).

Vehicles with 6-cylinder gasoline or 6-cylinder TDI engine:

- Insert the adapter -T40058- guide pins as follows:

• The large diameter -arrow 1- faces the engine.
• The small diameter -arrow 2- faces the adapter.

- Continue turning the crankshaft on the vibration damper 180º in the direction of the engine rotation using the Crankshaft Socket -T40058--arrow-.

  Note

The 6-cylinder TFSI gasoline engine is shown in the illustration.

- Tighten the bolt with the crankshaft in this position, refer to → Chapter "Overview - Flywheel and Dual Clutch".

- Continue turning the crankshaft 60º and tighten the remaining 5 bolts to the tightening specification, refer to → Chapter "Overview - Flywheel and Dual Clutch".

Vehicles with a 8-cylinder gasoline engine:

- Attach the Crankshaft Turning Tool -T40272- to the vibration damper bolts.

• The semi-round recess -arrow A- on the Crankshaft Turning Tool -T40272- must face the semi-round recess -arrow B- on the vibration damper.

  Note

Ignore the notch on the Crankshaft Turning Tool -T40272-.

- Turn the crankshaft at the vibration damper 180º further in the direction of the engine rotation -arrow- with Crankshaft Turning Tool -T40272- and the offset open-end wrench.

- Tighten the bolt with the crankshaft in this position, refer to → Chapter "Overview - Flywheel and Dual Clutch".

- Continue turning the crankshaft 60º and tighten the remaining 5 bolts to the tightening specification, refer to → Chapter "Overview - Flywheel and Dual Clutch".

All vehicles:

Install in reverse order of removal. Note the following:

- Install selector lever cable, refer to → Chapter "Selector Lever Cable, Removing and Installing".

- Install the starter, refer to → Electrical Equipment; Rep. Gr.27; Starter; Starter, Removing and Installing.

- Tighten the remaining engine/transmission connecting bolts -3 through 5-.

- Install the Transmission Fluid Cooling Valve -N509-, refer to → Rep. Gr.19; Coolant Pump/Thermostat; Coolant Valve, Removing and Installing.

- Install the coolant pipe, refer to → Rep. Gr.19; Coolant Pipes; Coolant Pipes, Removing and Installing.

- Installing the ATF cooler, refer to → Chapter "Overview - ATF Circuit".

- Attach the steering intermediate shaft to the steering gear, refer to → Suspension, Wheels, Steering; Rep. Gr.48; Steering Column; Steering Intermediate Shaft, Removing and Installing.

- Connections and routing, refer to → Wiring diagrams, Troubleshooting & Component locations.

- Install the driveshaft, refer to → Rep. Gr.39; Removal and Installation.

- Installing the drive axle and drive axle heat shield, refer to → Suspension, Wheels, Steering; Rep. Gr.40; Drive Axle; Overview - Drive Axle.

- Install the subframe heat shield, refer to → Body Exterior; Rep. Gr.66; Molding/Trim/Extensions/Trim Panels; Overview - Heat Shield.

- Install the subframe crossbrace, refer to → Suspension, Wheels, Steering; Rep. Gr.40; Subframe; Overview - Subframe.

- Install the fan shroud, refer to → Rep. Gr.19; Radiator/Coolant Fan; Fan Shroud, Removing and Installing.

- Fill the engine coolant, refer to → Rep. Gr.19; Cooling System/Coolant; Coolant, Draining and Filling.

- Install the plenum chamber bulkhead, refer to → Body Exterior; Rep. Gr.50; Bulkhead; Overview - Bulkhead.

- Install the exhaust system, refer to → Rep. Gr.26; Exhaust Pipes/Mufflers; Overview - Muffler.

- Install the drive axle covers and noise insulation, refer to → Body Exterior; Rep. Gr.66; Noise Insulation; Overview - Noise Insulation.

- Install the front wheels, refer to → Suspension, Wheels, Steering; Rep. Gr.44; Wheels and Tires.

- Observe measures after connecting the battery, refer to → Electrical Equipment; Rep. Gr.27; Battery; Battery, Disconnecting and Connecting.

  Caution

Danger of causing damage to the control modules due to the excess voltage.

Do not use a charger to jump start!

- Check and adjust the selector lever cable, refer to → Chapter "Selector Lever Cable, Checking and Adjusting".

- Check the ATF level and correct if necessary, refer to → Chapter "ATF Level, Checking".

- Check transmission fluid level and fill, refer to → Chapter "Transmission Fluid Level, Checking".

Transmission Tightening Specifications

  Note

• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine oil or transmission fluid are permissible, but lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance +- 15%.

S tronic transmission on the 6-cylinder or 8-cylinder gasoline engine

¹⁾ Mount the auxiliary adapter

²⁾ Bolt strength rating 10.9. There is no limit to the number of times steel bolts may be used.

³⁾ The bolts may be used two times.

S tronic transmission on 6-cylinder TDI engine

¹⁾ Mount the auxiliary adapter

²⁾ Bolt strength rating 10.9. There is no limit to the number of times steel bolts may be used.

³⁾ The bolts may be used two times.

• The aluminum bolts -2 through 10- can be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.
• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a ¹/₂ drive, which is inserted in to the vise, as illustrated.
• Bolts marked with an "X" may not be used again.

READ NEXT: