6-Speed Manual Gearbox 0B4 Four-Wheel Drive

Service
6-speed manual gearbox 0B4, four-wheel drive

Edition 01.2014
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
A005A402720
Audi A4 2008 ➤ , Audi A5 Coupé 2008 ➤
6-speed manual gearbox 0B4, four-wheel drive - Edition 01.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification of final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Transmission layout - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Exploded view - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Exploded view - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 24
1.7 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 24
1.8 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.10 Bleeding clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Exploded view - clutch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Exploded view - clutch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Tightening sequence - clutch module to drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Exploded view - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Removing and installing noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.8 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.9 Removing and installing gear detector switch F208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2 Removing and installing tunnel cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3 Removing and installing gearbox support with gearbox mounting . . . . . . . . . . . . . . . . . . . . 124
4.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Contents i
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1 Dismantling and assembling gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Overview of fitting locations - oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.1 Renewing cover for final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3 Front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4 Centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Exploded view - centre differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Removing and installing centre differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.3 Renewing oil seal for rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.4 Renewing oil seal for flange shaft (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ii Contents
00 – Technical data
1 Identification
(ARL003543; Edition 01.2014)
⇒ “1.1 Gearbox identification”, page 1
⇒ “1.2 Identification of final drive”, page 1
1.1 Gearbox identification

Location on gearbox
♦ -Arrow- code letters, serial number and gearbox part number
⇒ page 1
-Arrow 1- gearbox code letters and consecutive serial number

Example: 001379 KTV
Serial number Code letters
-Arrow 2- manual gearbox “0B4” with gearbox Part No. (e.g. 0B4
300 040 H)
Note
The code letters for the gearbox are also given on the vehicle data
stickers.
1.2 Identification of final drive

⇒ “1.2.1 Identification of final drive - rear final drive 0BC”,
page 1
⇒ “1.2.2 Identification of final drive - rear final drive 0BF and 0BE
(sport differential)”, page 3
1.2.1 Identification of final drive - rear final

drive 0BC
Note
♦ Code letters, allocation, ratio, capacities ⇒ Rear final drive;

Rep. gr. 00 ; Technical data
♦ For repairs on the propshaft or the rear final drive, refer to
Workshop Manual ⇒ Rear final drive; Rep. gr. 39 ; Propshaft ,
or ⇒ Rear final drive; Rep. gr. 39 ; Final drive .
1. Identification 1
Location on final drive

Final drive 0BC -arrow 1- and 0AR
Code letters and date of manufacture -arrow 2-
Final drive 0BC -arrow- and 0AR
Note
♦ The designation “0AR” always appears on the rear final drive

housing. The distinguishing features for final drives “0BC” and
“0AR” are housing modifications.
♦ An additional distinguishing feature is the position of the tap‐
ped holes -arrows- used to secure the cross member to the
rear final drive.
♦ On the final drive unit “0BC” there are 4 tapped holes
-arrows- in the final drive housing for securing the cross mem‐
ber. There is also an additional tapped hole below the prop‐
shaft flange, for securing the final drive to the subframe.
Code letters and date of manufacture for rear final drive

Example: JKS 15 03 07
I I I I
Code letters Day Month Year -2007-
of manufacture
Other information can be disregarded.
Note
When installing a new rear final drive unit, it is important to verify

not only the code letters of the final drive but also the PR No. and
the engine code of the vehicle in the ⇒ Electronic parts catalogue .
This is necessary to ensure that the correct version is installed.
2 Rep. gr.00 - Technical data

1.2.2 Identification of final drive - rear final

drive 0BF and 0BE (sport differential)
Note
♦ Code letters, allocation, ratio, capacities ⇒ Rear final drive;

Rep. gr. 00 ; Technical data
♦ For repairs on the propshaft or the rear final drive, refer to
Workshop Manual ⇒ Rear final drive; Rep. gr. 39 ; Propshaft ,
or ⇒ Rear final drive; Rep. gr. 39 ; Final drive .
Location on rear final drive

Classification of clutches -arrow 1-
Code letters and date of manufacture -arrow 2-
Note
The rear final drive units “0BE” and “0BF” can be identified by the
hydraulic control unit with superposition gears at the sides.
♦ -Arrow 1- Code letters -LFW-

♦ -Arrow 2- Manufacturing data of rear final drive
Exam‐ 08 12 09
ple:
I I I
Year -2008- Month Day
of manufacture
♦ -Arrow 3- Classification of clutch on right side (classification of
friction coefficients for clutch). Example: -272D-
♦ -Arrow 4- Classification of clutch on left side (classification of
friction coefficients for clutch). Example: -4A10-
Other information can be disregarded.
Note
When installing a new rear final drive unit, it is important to verify

not only the code letters of the final drive but also the PR No. and
the engine code of the vehicle in the ⇒ Electronic parts catalogue .
This is necessary to ensure that the correct version is installed.
1. Identification 3
2 Technical data
⇒ “2.1 Allocation of gearbox to engine”, page 4
⇒ “2.2 Capacities”, page 8
2.1 Allocation of gearbox to engine

⇒ “2.1.1 Allocation of gearbox to engine - Audi A4 2008 ►”, page
4
⇒ “2.1.2 Allocation of gearbox to engine, Audi A5 Coupé 2008 ►”,
page 6
⇒ “2.1.3 Allocation of gearbox to engine - Audi A5 Sportback 2008
►”, page 7
2.1.1 Allocation of gearbox to engine - Audi A4

2008 ►
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Gear oil specification
♦ Correct type of flange shafts
♦ Correct type of dual-mass flywheel
♦ Correct type of clutch plate and pressure plate
♦ Correct type of rear final drive according to code letters and
PR number
Manual gearbox 6-speed 0B4, four-wheel drive
Code letters KMR KMU KUN
Manufactured from 01.09 11.07 03.09
to 03.10 03.10 03.10
Allocation Model Audi A4 2008 ► Audi A4 2008 ► Audi A4 2008 ►
Engine 3.0 ltr. TFSI - 245 kW 3.0 ltr. TDI - 176 kW 3.0 ltr. TDI - 176 kW all‐
S4 road
Ratio Final drive 31 : 9 = 3.444 31 : 9 = 3.444 29 : 8 = 3.625
Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 41 : 19 = 2.158 39 : 20 = 1.950 39 : 20 = 1.950
3rd gear 38 : 25 = 1.520 35 : 29 = 1.207 35 : 29 = 1.207
4th gear 34 : 30 = 1.133 28 : 33 = 0.848 28 : 33 = 0.848
5th gear 34 : 37 = 0.919 28 : 43 = 0.651 28 : 43 = 0.651
6th gear 35 : 45 = 0.778 28 : 52 = 0.538 28 : 52 = 0.538
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222
Overall ratio iov. in top gear 2.864 1.983 2.087

Code letters LDD LDE LPD
to 05.08
Engine 3.0 ltr. TDI - 176 kW 3.0 ltr. TDI - 176 kW 3.0 ltr. TDI - 176 kW


Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 20 = 1.950 39 : 20 = 1.950 39 : 20 = 1.950
3rd gear 35 : 29 = 1.207 35 : 29 = 1.207 35 : 29 = 1.207
4th gear 28 : 33 = 0.848 28 : 33 = 0.848 28 : 33 = 0.848
5th gear 28 : 43 = 0.651 28 : 43 = 0.651 28 : 43 = 0.651
6th gear 28 : 52 = 0.538 28 : 52 = 0.538 28 : 52 = 0.538
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222

Code letters LPE LPF MZZ
to
Engine 3.0 ltr. TFSI - 245 kW 3.0 ltr. TDI - 176 kW all‐ 3.0 ltr. TDI - 176 kW
road
Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 41 : 19 = 2.158 39 : 20 = 1.950 39 : 20 = 1.950
3rd gear 38 : 25 = 1.520 35 : 29 = 1.207 35 : 29 = 1.207
4th gear 34 : 30 = 1.133 28 : 33 = 0.848 28 : 33 = 0.848
5th gear 34 : 37 = 0.919 28 : 43 = 0.651 28 : 43 = 0.651
6th gear 35 : 45 = 0.778 28 : 52 = 0.538 28 : 52 = 0.538
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222

Code letters NAA
Manufactured from 01.12
to
Allocation Model Audi A4 2008 ►
Engine 3.0 ltr. TFSI - 245 kW
Ratio Final drive 31 : 9 = 3.444
Intermediate 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667
2nd gear 41 : 19 = 2.158
3rd gear 38 : 25 = 1.520
4th gear 34 : 30 = 1.133
5th gear 34 : 37 = 0.919
2. Technical data 5

6th gear 35 : 45 = 0.778
Reverse gear 29 : 9 = 3.222
Overall ratio iov. in top gear 2.864
2.1.2 Allocation of gearbox to engine, Audi A5

Coupé 2008 ►
logue .
PR number
Code letters JJQ KMU KMV
to 03.10 03.10 05.10
Engine 4.2 ltr. - 260 kW 3.0 ltr. TDI - 176 kW 4.2 ltr. - 260 kW S5
Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 41 : 19 = 2.158 39 : 20 = 1.950 41 : 19 = 2.158
3rd gear 38 : 25 = 1.520 35 : 29 = 1.207 38 : 25 = 1.520
4th gear 34 : 30 = 1.133 28 : 33 = 0.848 34 : 30 = 1.133
5th gear 34 : 37 = 0.919 28 : 43 = 0.651 34 : 37 = 0.919
6th gear 35 : 45 = 0.778 28 : 52 = 0.538 35 : 45 = 0.778
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222

Code letters LDD LPC LPD
to 05.08
Engine 3.0 ltr. TDI - 176 kW 4.2 ltr. - 260 kW S5 3.0 ltr. TDI - 176 kW
Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 20 = 1.950 41 : 19 = 2.158 39 : 20 = 1.950
3rd gear 35 : 29 = 1.207 38 : 25 = 1.520 35 : 29 = 1.207


4th gear 28 : 33 = 0.848 34 : 30 = 1.133 28 : 33 = 0.848
5th gear 28 : 43 = 0.651 34 : 37 = 0.919 28 : 43 = 0.651
6th gear 28 : 52 = 0.538 35 : 45 = 0.778 28 : 52 = 0.538
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222

Code letters NAA
Manufactured from 03.12
to
Allocation Model Audi A4 2008 ►
Engine 3.0 ltr. TFSI - 245 kW
Ratio Final drive 31 : 9 = 3.444
Intermediate 31 : 29 = 1.069
drive
Z2 : Z1 = i 1st gear 33 : 9 = 3.667
2nd gear 41 : 19 = 2.158
3rd gear 38 : 25 = 1.520
4th gear 34 : 30 = 1.133
5th gear 34 : 37 = 0.919
6th gear 35 : 45 = 0.778
Reverse gear 29 : 9 = 3.222
Overall ratio iov. in top gear 2.864
2.1.3 Allocation of gearbox to engine - Audi A5

Sportback 2008 ►
logue .
PR number
Code letters KMU LPD MZZ
to 03.10
Allocation Model Audi A5 Sportback Audi A5 Sportback Audi A5 Sportback
2008 ► 2008 ► 2008 ►
Engine 3.0 ltr. TDI - 176 kW 3.0 ltr. TDI - 176 kW 3.0 ltr. TDI - 176 kW
Intermediate 31 : 29 = 1.069 31 : 29 = 1.069 31 : 29 = 1.069
drive
2. Technical data 7

Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 20 = 1.950 39 : 20 = 1.950 39 : 20 = 1.950
3rd gear 35 : 29 = 1.207 35 : 29 = 1.207 35 : 29 = 1.207
4th gear 28 : 33 = 0.848 28 : 33 = 0.848 28 : 33 = 0.848
5th gear 28 : 43 = 0.651 28 : 43 = 0.651 28 : 43 = 0.651
6th gear 28 : 52 = 0.538 28 : 52 = 0.538 28 : 52 = 0.538
Reverse gear 29 : 9 = 3.222 29 : 9 = 3.222 29 : 9 = 3.222
2.2 Capacities
Capacity of manual gearbox 3.8 ltr.
♦ Gear oil specifications ⇒ Electronic parts catalogue

3 Transmission layout
⇒ “3.1 Transmission layout - four-wheel drive”, page 9
3.1 Transmission layout - four-wheel drive
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Drive plate
❑ With needle bearing for
gearbox input shaft
3 - Clutch module
❑ Consists of pressure
plate, clutch plate and
dual-mass flywheel with
flange for drive plate
4 - Front differential
5 - Input shaft (main shaft)
6 - Front pinion shaft (side
shaft)
7 - Output shaft
8 - Manual gearbox
9 - Centre differential
10 - Propshaft
11 - Rear pinion shaft
12 - Rear differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
S - Spur gears (intermediate
drive)
❑ With beveloid teeth
A1 - Front final drive
A2 - Rear final drive
3. Transmission layout 9
4 Repair instructions
⇒ “4.1 General repair instructions”, page 10
4.1 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools catalogue .
Gearbox
♦ Servicing ⇒ Servicing manual gearbox; Rep. gr. 34 ; Dis‐
mantling and assembling gearbox
♦ Allocate bolts and other components according to gearbox
code letters, refer to ⇒ Electronic parts catalogue ⇒ page 4 .
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 127 .
♦ Capacities and specifications ⇒ page 8
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing gearbox ensure dowel sleeves are correctly
seated.
Sealants
♦ Thoroughly clean housing contact surfaces before applying
sealing paste.
♦ Apply sealing paste - AMV 188 001 02- evenly and not too
thickly.
♦ Breather holes must remain free of sealing paste.

O-rings, seals, oil seals and gaskets

♦ Always renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease - G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing gaskets and oil seals, check and, if necessary,
top up oil level in gearbox ⇒ page 127 .
4. Repair instructions 11
Locking elements
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then apply locking fluid -
AMV 185 101 A1- to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Do not install shims which are damaged or not in perfect con‐
dition.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
♦ Grease needle bearing for gearbox input shaft in drive plate.
♦ Lubricate all bearings in gearbox housing with gear oil before
installing.
Clutch mechanism
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the clutch slave
cylinder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the clutch slave cylinder. As a
result the clutch slave cylinder will be destroyed.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures
⇒ “1.6 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 24 ).

♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦ Blow out clutch module with compressed air only.
♦ The brake fluid in the clutch system should be changed at the
same intervals as the brake fluid in the brake system ⇒ Main‐
tenance ; Booklet 405 ; Description of work; Brake fluid:
changing (every 2 years) .
4. Repair instructions 13
5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
14
5.1 Overview of fitting locations - electrical

components
Gear detector switch - F208- item -2-
– ⇒ “1.9 Removing and installing gear detector switch F208 ”,
page 54
Gear detection sensor - G604- item -1-

– ⇒ “1.9.1 Removing and installing gear detection sensor G604
”, page 57
⇒ “5.1 Overview of fitting locations - electrical components”, page
14

30 – Clutch
1 Clutch mechanism
⇒ “1.1 Exploded view - pedal cluster”, page 15
⇒ “1.2 Exploded view - clutch hydraulics”, page 19
⇒ “1.3 Exploded view - clutch release mechanism”, page 20
⇒ “1.4 Removing and installing over-centre spring”, page 20
⇒ “1.5 Removing and installing clutch pedal”, page 23
⇒ “1.6 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 24
⇒ “1.7 Checking clutch master cylinder and clutch slave cylinder”,
page 24
⇒ “1.8 Removing and installing clutch master cylinder”,
page 25
⇒ “1.9 Removing and installing clutch slave cylinder”, page 29
⇒ “1.10 Bleeding clutch hydraulics”, page 31
1.1 Exploded view - pedal cluster

⇒ “1.1.1 Exploded view - pedal cluster, LHD vehicles”,
page 15
⇒ “1.1.2 Exploded view - pedal cluster, RHD vehicles”,
page 16
1.1.1 Exploded view - pedal cluster, LHD ve‐

hicles
Caution
Risk of malfunction
♦ The travel of the clutch pedal and the brake pedal must
not be restricted due to additional floor mats or the like.
Note
♦ Apply grease - G 000 450 02- to all bearings and contact sur‐
faces.
♦ Make sure that no brake fluid escapes into the footwell, the
plenum chamber or onto the gearbox below. If this does hap‐
pen, clean the affected area thoroughly.
1. Clutch mechanism 15
1 - Mounting bracket
❑ With brake pedal
❑ Removing and installing
⇒ page 25
2 - Bearing bush
3 - Clutch pedal
⇒ page 25
4 - Clutch pedal stop
5 - Locking pin
❑ For clutch master cylin‐
der
❑ Grease bearing surface
6 - Pivot pin for clutch pedal
7 - Bearing shell
❑ Located in clutch pedal
8 - Over-centre spring
❑ Black side points to‐
wards clutch pedal
❑ Note different bearing
positions in mounting
bracket ⇒ page 22
⇒ page 20
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
9 - Bearing shell
positions in mounting
bracket ⇒ page 22
10 - Seal
❑ Renew
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 25
❑ Grease mounting eye of pushrod
12 - Clutch position sender - G476-
❑ Clutch pedal switch - F36- and clutch pedal switch for engine start - F194- are integrated
❑ Can only be renewed together with clutch master cylinder ⇒ Item 11 (page 16)
1.1.2 Exploded view - pedal cluster, RHD ve‐

hicles
Caution
Risk of accident.
♦ The travel of the brake pedal must not be restricted with
additional floor mats or the like.
16 Rep. gr.30 - Clutch

Note
♦ Apply grease - G 000 450 02- to all bearings and contact sur‐
faces.
♦ Make sure that no brake fluid escapes into the footwell, the
plenum chamber or onto the gearbox below. If this does hap‐
1 - Clutch pedal
2 - Clutch pedal stop
3 - Locking pin
❑ For clutch master cylin‐
der
❑ Grease bearing surface
4 - Bearing bush
5 - Pivot pin for clutch pedal
6 - Retaining clip
7 - Bearing
positions in clutch pedal
⇒ page 22
8 - Bearing shell
9 - Over-centre spring
❑ Black side points to‐
wards clutch pedal
positions in clutch pedal
⇒ page 18
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
❑ Remove and install with
assembly clip - T40025-
10 - Bearing shell
11 - Seal
❑ Renew
12 - Clutch position sender -
G476-
❑ Clutch pedal switch - F36- and clutch pedal switch for engine start - F194- are integrated
❑ Can only be renewed together with clutch master cylinder ⇒ Item 13 (page 17)
❑ Grease mounting eye of pushrod
❑ With brake pedal
15 - Seal
16 - Retaining clip
17 - Bearing bush
18 - Bolt
❑ 2x
❑ 8 Nm
Installing over-centre spring

– Clip bearing -1- into corresponding position on clutch pedal.
Bearing position Vehicles with:
• “I” -arrow A-: ♦ 3.0 ltr. TFSI engine
♦ 3.0 ltr. TDI engine
♦ 4.2 ltr. FSI engine
• “II” -arrow B- ♦ Not used on vehicles with »0B4

gearbox«
– Insert over-centre spring with assembly clip - T40025- .

• White side of over-centre spring faces bearing -1-.

1.2 Exploded view - clutch hydraulics

Observe notes on removing and installing clutch master cylinder
and slave cylinder ⇒ page 24 .
1 - Clutch slave cylinder

❑ Do not operate clutch
pedal after slave cylin‐
der has been removed
⇒ page 29
❑ After working on hy‐
draulic clutch mecha‐
nism, bleed clutch sys‐
tem ⇒ page 31
❑ Do not allow brake fluid
to come into contact
with gearbox.
2 - Bleeder screw
❑ 5.5 Nm
❑ Follow correct proce‐
dure when bleeding
⇒ page 31
❑ If bleeder screw has
broken off, it can be re‐
moved with 3 mm Allen
key
3 - Dust cap
4 - Grommet
5 - Pipe/hose assembly
❑ With frequency modula‐
tor (vibration damper)
Note
A one-piece pipe/hose assembly

without frequency modulator is in‐
stalled on Audi A5 vehicles up to
Chassis No. 8T-8-000100.
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Connecting and disconnecting ⇒ page 20
❑ Allocation for LHD and RHD vehicles ⇒ Electronic parts catalogue
6 - Retaining clip
7 - O-ring
❑ Renew if damaged
❑ Lubricate with brake fluid before installing
8 - Supply hose
❑ For clutch master cylinder
❑ With integrated sealing grommets
❑ Renew supply hose if sealing grommets are damaged
9 - Brake fluid reservoir
10 - Retaining clip
❑ To remove pipe/hose assembly, pull out clip as far as stop ⇒ page 20 .

❑ After working on hydraulic clutch mechanism, bleed clutch system ⇒ page 31
12 - Pipe
❑ Connecting and disconnecting ⇒ page 20
❑ For correct version, refer to ⇒ Electronic parts catalogue
13 - Bracket
❑ For pipe
❑ Attached to gearbox
14 - Bolt
❑ 20 Nm
15 - O-ring
❑ Renew if damaged
❑ Lubricate with brake fluid before installing
16 - Retaining clip
❑ To remove pipe/hose assembly, pull out clip as far as stop ⇒ page 20 .
17 - Bolt
❑ 20 Nm
❑ Clutch slave cylinder to gearbox
Connecting and disconnecting pipe/hose assembly

Disconnecting
– Release retaining clip -A- using a screwdriver and pull out as
far as stop.
– Pull off pipe/hose assembly.
Connecting
Note
Renew O-ring if damaged.
– Press retaining clip -A- in as far as it will go.

– Push pipe/hose assembly into connection until it engages au‐
dibly.
– Pull on pipe/hose assembly to check it is secure.
1.3 Exploded view - clutch release mecha‐

nism
• For a detailed description please refer to the Workshop Man‐
ual ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch mech‐
anism; Exploded view - clutch release mechanism .
1.4 Removing and installing over-centre

spring
Special tools and workshop equipment required

♦ Assembly clip - T40025-
♦ Removal wedge - 3409-
Removing
– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Shelves / trim panels; Removing
and installing dash panel cover (driver side) .
– If fitted, unplug connector -C-.

– Unscrew bolt -A- and remove footwell vent (left-side) -B- ⇒
Heating, air conditioning; Rep. gr. 87 ; Air duct system; Re‐
moving and installing footwell vent (driver side) .
– Move clutch pedal -1- slightly in direction of -arrow-. Press as‐

sembly clip - T40025- onto over-centre spring -2- while over-
centre spring is compressed.
– Depress clutch pedal -1- fully to stop and remove over-centre
spring -2- downwards with assembly clip - T40025- .
Installing over-centre spring

– Clip bearing shell -1- into appropriate bearing position.
Installation position of over-centre spring -2-
• Bearing position “I” ♦ Vehicles with 6-cylinder en‐
-arrow A- gine
♦ Vehicles with 8-cylinder en‐
gine
• Bearing position “II” ♦ Not used on vehicles with

-arrow B- »0B4 gearbox«
• Clip bearing shell -1- into appropriate bearing position.

• Black side of over-centre spring -arrow C- faces clutch pedal.
– Depress clutch pedal -1- fully to stop and install over-centre

spring -2- with assembly clip - T40025- .
– Pull clutch pedal -1- back to rest position. Take assembly clip
- T40025- off over-centre spring -2- while over-centre spring
is compressed.
– Install footwell vent -B- and tighten bolt -A- ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air duct system; Removing and
installing footwell vent (driver side) .
– If fitted, plug in connector -C-.
– Install dash panel cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Shelves / trim panels; Removing and
installing dash panel cover (driver side) .

1.5 Removing and installing clutch pedal

Removing
– Remove mounting bracket ⇒ Brake system; Rep. gr. 46 ;
Brake pedal; Removing and installing mounting bracket .
– Remove over-centre spring -2- ⇒ page 20 .
– Remove locking pin -1-.

– Remove pivot pin -2- by lifting retaining tab -arrow A- and turn‐
ing pivot pin in direction of -arrow B-.
– Pull out pivot pin -2- and remove clutch pedal -3-.
Installing
Installation is carried out in reverse sequence; note the following:
– Apply grease - G 000 450 02- to all bearings and contact sur‐
faces.
– Install clutch pedal -3-, push in pivot pin -1- and lock in direction
of -arrow A-. Bottom of retaining tab -2- should engage at pedal
bracket.
– Insert locking pin -4-. Shoulder on pin -arrow B- must be in‐
troduced into groove on clutch pedal.
– Install over-centre spring ⇒ page 22 .
– Install mounting bracket ⇒ Brake system; Rep. gr. 46 ; Brake
pedal; Exploded view - brake pedal .
1.6 Notes on removing and installing clutch

master cylinder and slave cylinder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective, you must first carry out
the appropriate function check ⇒ page 24 .
♦ If slave cylinder is removed from gearbox with hose/pipe as‐
sembly still attached, make sure you do not press clutch pedal.
Otherwise, the piston will be pressed out of the slave cylinder
and be destroyed.
♦ After installing the slave cylinder carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. 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.
1.7 Checking clutch master cylinder and

clutch slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ Check that footwell trim and/or floor mats are not trapped.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time.
♦ This could impair the self-bleeding function of the clutch sys‐
tem as the vent opening in the clutch master cylinder can no
longer function.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 31 .

High pedal force:

♦ Mechanical fault on clutch plate or pressure plate ⇒ Servicing
manual gearbox; Rep. gr. 30 ; Clutch; Exploded view - clutch
Pedal forces:
Single-plate SAC clutch:
- approx. 140 N for complete service life of the clutch.
Twin-plate SAC clutch:
- approx. 125 N for complete service life of the clutch.
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 31 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines.
♦ Needle bearing in drive plate defective (centring bearing for
input shaft); renew needle bearing ⇒ Rep. gr. 13 ; Cylinder
block (gearbox end); Renewing needle bearing in drive plate .
♦ Foreign body in clutch system.
♦ Mechanical fault on clutch plate or pressure plate ⇒ Servicing
manual gearbox; Rep. gr. 30 ; Clutch; Exploded view - clutch
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel sleeves
between engine and gearbox).
1.8 Removing and installing clutch master

cylinder
♦ Hose clamps, up to 25 mm - 3094-
♦ Open ring spanner, 32 mm - 3355-
Removing
– Observe notes on removing and installing clutch master cyl‐
inder and slave cylinder ⇒ page 24 .
Caution
Risk of damage to electronic components.

♦ Observe the correct procedure for disconnecting the bat‐
tery.
– Disconnect earth wire -2- from battery terminal ⇒ Electrical

system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
– Detach seal -arrow-.

– Depending on version, remove left section -3- or entire plenum
chamber cover ⇒ General body repairs, exterior; Rep. gr. 50 ;
Bulkhead; Removing and installing plenum chamber cover .
– Remove electronics box in engine compartment ⇒ Electrical

system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics
boxes; Removing and installing electronics box .

Note
In the following steps make sure that no brake fluid escapes into
the plenum chamber or onto the gearbox below. If this does hap‐
– Clamp off supply hose -2- from brake fluid reservoir using hose
clamp - 3094- . Disconnect hose from clutch master cylinder
-1- and plug hose.
– Release retaining clip -3- using a screwdriver and pull out to
limit stop.
– Pull off pipe/hose assembly -4-.
Note
Leave connector -item 5- connected.
– Remove over-centre spring -2- ⇒ page 20 .
– Pull locking pin -1- out of clutch pedal -3-.
Note
-Item 2- and -arrows A, B- can be disregarded.
– Release clutch master cylinder in direction of -arrow- using

open ring spanner, 32 mm - 3355- .
– Pull out clutch master cylinder -1- and guide it out through
opening for engine wiring harness.
– Release connector -5- and unplug.
Installing
– Plug in connector -5-.
– Install clutch master cylinder -1-.
– Pull clutch master cylinder into footwell in direction of

-arrow A-. At the same time lock clutch master cylinder in di‐
rection of -arrow B- using open ring spanner, 32 mm - 3355- .
– Insert locking pin -4-. Shoulder on pin -arrow B- must be in‐

troduced into groove on clutch pedal.
Note
-Items 1, 2, 3- and -arrow A- can be disregarded.
– Install over-centre spring ⇒ page 22 .

– Press in retaining clip -3- as far as stop.
Note
If damaged, renew O-ring for pipe/hose assembly -4-.
– Insert pipe/hose assembly -4- into clutch master cylinder and

make sure that it engages audibly.
– Slide on supply hose -2- as far as stop.
– Remove hose clamp, up to 25 mm - 3094- .
– Bleed clutch system ⇒ page 31 .
– Install electronics box in engine compartment ⇒ Electrical
system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics
boxes; Removing and installing electronics box .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Follow steps required after connecting battery ⇒ Electrical
battery .
1.9 Removing and installing clutch slave

cylinder
♦ Torque wrench - V.A.G 1331-
♦ Engine bung set - VAS 6122-
♦ Safety goggles
Removing
– Observe notes on removing and installing clutch master cyl‐
inder and slave cylinder ⇒ page 24 .
Note
Do not allow brake fluid to come into contact with the gearbox. If
necessary, clean the gearbox housing.
– Remove rear noise insulation (loosen fasteners -2- and -3-).
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– Release retaining clip -2- using a screwdriver and pull out to

limit stop.
– Disconnect hose from clutch slave cylinder and plug hose.
– Remove bolt -3- and pull out clutch slave cylinder -1- to the
rear.
Note
Seal off open lines and connections with clean plugs from engine
bung set - VAS 6122- to prevent dirt from entering.
Installing clutch slave cylinder

Note
♦ Renew O-ring if damaged.

♦ If the clutch slave cylinder is inserted at an angle, there is a
danger that the operating rod will be guided past the clutch
release lever.

– When installing, press in clutch slave cylinder -1- so that se‐

curing bolt -3- can be fitted easily. Tightening torque
⇒ Item 17 (page 20)
– Press in retaining clip -2- as far as stop.
– Push pipe into clutch slave cylinder until it engages audibly.
– Bleed clutch system ⇒ page 31 .
– Install rear noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
1.10 Bleeding clutch hydraulics

♦ Brake filling and bleeding equipment - VAS 5234- or Brake
filling and bleeding equipment - V.A.G 1869-
♦ Brake fluid specification ⇒ Brake system; Rep. gr. 47 ; Hy‐

draulic system
Procedure
Note
♦ The clutch system must be bled after performing work on the

hydraulic clutch mechanism.
♦ When performing the following steps, make sure that no brake
fluid escapes onto the gearbox.
♦ Open the bleeder screw before switching on the bleeding ap‐
pliance.
♦ Before bleeding the clutch system, pull back the clutch pedal
to the normal position and top up brake fluid to “Max” marking
on brake fluid reservoir.
♦ The brake fluid in the clutch system should be changed at the
same intervals as the brake fluid in the brake system ⇒ Main‐
tenance ; Booklet 405 ; Description of work; Brake fluid:
changing (every 2 years) .
– Connect brake filling and bleeding equipment - VAS 5234- or

-V.A.G 1869- , but do not switch on at this stage ⇒ Brake
system; Rep. gr. 47 ; Hydraulic system; Bleeding hydraulic
system (normal bleeding procedure) .
– Connect bleeder hose -A- to clutch slave cylinder and open

bleeder screw -arrow-.
– Connect bleeder hose to pressure hose of fluid collector bottle.
– Switch on bleeding appliance and allow about 100 cm3 of
brake fluid to drain out.
• Operating pressure 2.0 bar
Note
Ensure bleeder hose is correctly fitted during bleeding operation.
– Tighten bleeder screw; tightening torque ⇒ Item 2 (page 19) .

– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
tion .

2 Clutch
⇒ “2.1 Exploded view - clutch module”, page 33
⇒ “2.2 Exploded view - clutch unit”, page 34
⇒ “2.3 Tightening sequence - clutch module to drive plate”, page
34
2.1 Exploded view - clutch module
Note
Servicing clutch module -2- ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch
A - Locating pins
❑ Not fitted in all vehicles
❑ When clutch module -2-
is bolted onto drive plate
-1-, locating pins -A- (if
provided) must engage
in locating holes -B-
B - Locating hole
❑ When clutch module -2-
is bolted onto drive plate
-1-, locating pins -A- (if
provided) must engage
in locating holes -B-
Caution
An incorrectly installed
clutch causes functional
problems.
If♦the locating pins on the
drive plate -A- are not lo‐
cated in the holes on the
clutch module -B-, this
will cause serious clutch
malfunctions.
1 - Drive plate
❑ 4-cylinder engine:
3 holes with threaded
sleeves
❑ 6-cylinder or 8-cylinder
engine: 6 holes with
threaded sleeves
❑ With needle bearing
⇒ Rep. gr. 13 ; Cylinder
2. Clutch 33
block (gearbox end);

Renewing needle bearing in drive plate
2 - Clutch module
❑ With flange for drive plate
❑ Components: dual-mass flywheel, clutch plate and clutch pressure plate
❑ Removing and installing ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch; Removing and installing
clutch module
❑ Servicing ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch
3 - Bolt
❑ 60 Nm
❑ Secures dual-mass flywheel to drive plate
❑ 6x
❑ Always renew
❑ Follow correct tightening sequence ⇒ page 34
2.2 Exploded view - clutch unit

• For a detailed description please refer to the Workshop Man‐
ual ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch; Explo‐
ded view - clutch mechanism .
2.3 Tightening sequence - clutch module to

drive plate
♦ Ring spanner insert, 16 mm - V.A.G 1332/14-
• Use new bolts.

• Tightening torque ⇒ Item 3 (page 34)
• Tighten bolts using ring spanner insert, 16 mm - V.A.G
1332/14- .

• Operate parking brake or counterhold propshaft using coun‐

terhold tool - T10172- and -T10172/5- .
Note
The next step is only required if a drive plate with locating pins
-2- is installed.
Caution
An incorrectly installed clutch causes functional problems.

♦ If the locating pins on the drive plate -2- are not located in
the holes on the clutch module -1-, this will lead to con‐
siderable functional problems of the clutch.
– In addition, align drive plate with clutch module so that locating

pins -2- (if provided) on drive plate can engage in large holes
-1- on clutch module.
– Engage 6th gear by pulling out selector shaft -1- and shifting
gearbox selector lever -2- forwards in direction of -arrow-.
Note
The following step is essential to ensure that the clutch module

makes even and proper contact on the drive plate and does not
cant.
– Turn both front wheels together in one direction until the clutch
module has turned through one complete revolution (360°).
• The inspection hole -arrow- should be visible again in the re‐
cess on the gearbox housing.
2. Clutch 35
– Install first bolt -arrow- and tighten hand-tight (2 Nm).

– Turn both front wheels so that clutch module turns 180° further
in direction of engine rotation.
– Now install second bolt and tighten to specified torque
⇒ Item 3 (page 34) .
– Tighten remaining five bolts to specified torque (including first
bolt installed), turning clutch module 60° further each time

34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Installation position - selector mechanism”, page 37
⇒ “1.2 Exploded view - gear knob and cover”, page 38
⇒ “1.3 Exploded view - selector mechanism”, page 39
⇒ “1.4 Removing and installing gear knob”, page 41
⇒ “1.5 Removing and installing noise insulation”, page 42
⇒ “1.6 Removing and installing selector mechanism”, page 43
⇒ “1.7 Adjusting selector mechanism”, page 48
⇒ “1.8 Renewing selector shaft oil seal”, page 51
⇒ “1.9 Removing and installing gear detector switch F208 ”, page
54
1.1 Installation position - selector mechanism

-Arrow A- gear selection movement
-Arrow B- gate selection movement
1 - Connecting rod
2 - Push rod
3 - Selector rod
1. Selector mechanism 37
4 - Gearbox selector lever
1.2 Exploded view - gear knob and cover
1 - Gear knob
❑ With gear lever boot
⇒ page 41
2 - Clamp
❑ Secures gear knob to
gear lever
❑ Secure with hose clip
pliers - V.A.G 1275-
3 - Boot
❑ Only supplied together
with support ring
⇒ page 42 together
with noise insulation
4 - Support ring
❑ Only supplied together
with boot
5 - Noise insulation
⇒ page 42
6 - Gasket
7 - Nut
❑ 8 Nm
❑ For gear lever bearing
9 - Gear lever with gear lever
bearing
38 Rep. gr.34 - Controls, housing

1.3 Exploded view - selector mechanism
1 - Circlip
❑ Take out before remov‐
ing ball
2 - Spacer bush
3 - Spring
4 - Ball guide
❑ Do not grease
5 - Ball
❑ Do not grease
6 - Damper
❑ For gear lever bearing
❑ Do not grease
7 - Bolt
❑ 23 Nm
8 - Clamping plate
❑ Do not grease
9 - Gear lever
❑ Bend points towards
rear
❑ Grease gear lever stops
and guide for reverse
gear detent; for grease
refer to ⇒ Electronic
parts catalogue
❑ Grease contact surfa‐
ces for joint
⇒ Item 12 (page 39) ;
for grease refer to ⇒
Electronic parts cata‐
logue
10 - Spacer tube
❑ Grease outside circumference; for grease refer to ⇒ Electronic parts catalogue
11 - Gear lever bearing
❑ Do not grease
12 - Joint
❑ Between selector rod and gear lever
❑ Grease contact surfaces for gear lever; for grease refer to ⇒ Electronic parts catalogue
13 - Bolt
❑ For joint ⇒ Item 12 (page 39)
14 - Bolt
❑ 23 Nm
15 - Nut
❑ 10 Nm
16 - Selector rod
17 - Push rod
❑ With bolt and washer
18 - Nut
❑ 20 Nm
❑ Always renew
19 - Bolt
❑ 4 Nm
20 - Gearbox selector lever
Caution
Risk of damage to selec‐
tor shaft in gearbox.
Do
♦ not prise off or knock
off the gearbox selector
lever with a lever or ham‐
mer.
Always
♦ use puller -
T40160- when removing
the gearbox selector lev‐
er.
❑ Pulling off ⇒ page 40

❑ Install so that gap in splines aligns with selector shaft
21 - Sealing collar
22 - Ball socket
❑ Grease pivot for gearbox selector lever ⇒ Item 20 (page 40) if necessary; for grease refer to ⇒ Electronic
parts catalogue
23 - Bearing bush
❑ To remove, pull off retaining clip ⇒ Item 26 (page 40)
24 - Connecting rod
❑ To remove, pull off retaining clip ⇒ Item 26 (page 40)
25 - Bolt
❑ 20 Nm
26 - Retaining clip
27 - Bolt
❑ 20 Nm
Detaching gearbox selector lever -1-
Caution
Risk of damage to selector shaft in gearbox.

♦ Do not prise off or knock off the gearbox selector lever
-1- with a lever or hammer.
♦ Always use puller - T40160- when removing the gearbox
selector lever.
– Apply puller - T40160- and pull off gearbox selector lever -1-.

1.4 Removing and installing gear knob
Note
The gear knob is removed together with the gear lever boot.

♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1275-
Removing
– Prise out gear lever boot using removal wedge - 3409-
-arrows- and pull upwards to detach.
– Pull boot up and over gear knob.

– Open clip -arrow- and pull off gear knob together with boot.
Installing
Perform installation in reverse sequence of removal.
– Secure clip -arrow- using hose clip pliers - V.A.G 1275- .
1.5 Removing and installing noise insulation

Removing
– Switch off ignition.
– Remove gear knob with gear lever boot ⇒ page 41 .
– Remove multimedia system operating unit - E380- ⇒ Com‐
munication; Rep. gr. 91 ; Infotainment system; Removing and
installing multimedia system operating unit - E380- .
– Release retaining tabs -1- in direction of -arrow-. At the same

time, lift rear end of noise insulation slightly.
– Pull noise insulation out of tabs -3-.
– Pull boot -2- off gear lever in direction of -arrow-.
Installing
– Insert noise insulation into tabs -1- and press down until re‐
taining tabs -2- engage.
– Pull boot over gear lever and into rounded groove -arrow A-.
– Press support ring in boot over gear lever bearing as far as
stop in direction of -arrow B-.
The remaining installation steps are carried out in reverse se‐
quence; note the following:
– Install multimedia system operating unit - E380- ⇒ Commu‐
nication; Rep. gr. 91 ; Infotainment system; Removing and
– Install gear knob with gear lever boot ⇒ page 41 .

1.6 Removing and installing selector mech‐

anism
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Gearbox support - T10337-
♦ Puller - T40160-
Removing
– Switch off ignition.
– Remove gear knob with gear lever boot ⇒ page 41 .
– Remove air conditioner operating and display unit ⇒ Heating,
air conditioning; Rep. gr. 87 ; Operating and display unit; Re‐
moving and installing operating and display unit .
– Remove multimedia system operating unit - E380- ⇒ Com‐

munication; Rep. gr. 91 ; Infotainment system; Removing and
– Remove ashtray (front) -1- ⇒ General body repairs, interior;

Rep. gr. 68 ; Centre console; Removing and installing ashtray
(front) .
– Remove noise insulation above selector mechanism

⇒ page 42 .
– Remove nuts -arrows-.

Note
The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.
– Disconnect exhaust system at clamp(s) -arrows-.
– If fitted, remove bolts -arrows- and detach heat shield -A- for
propshaft.
Propshaft with bolted connection at gearbox end:

– Remove securing bolts from connection between propshaft
and gearbox (counterhold using counterhold tool - T10172-
and -T10172/5- ).
– Slide propshaft together towards rear final drive. The constant
velocity joints can be moved axially.
– Tie propshaft up to one side.
Propshaft with splined connection at gearbox end:
– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
Continued for all vehicles

– Remove bolts -4- and detach cross piece -3-.
– Remove nuts -1- and detach heat shield -2-.
– Support gearbox using engine and gearbox jack - V.A.G 1383

A- with gearbox support - T10337- attached.
– Slightly lift gearbox with engine and gearbox jack - V.A.G 1383
A- .
WARNING
Risk of accident.
♦ Engine and gearbox jack - V.A.G 1383 A- must remain in
position when work is being carried out and must not be
left unattended.
– Remove bolts -arrows- for tunnel cross member.
– Lower gearbox by dimension -a- using engine and gearbox

jack - V.A.G 1383 A- .
• Dimension -a- = 70 mm (maximum)

– Remove bolt -1- for push rod and bolt -3- for connecting rod.
Note
-Item 2- can be disregarded.
– Remove nut -1-.
Note
Caution

– Remove heat shield below selector mechanism ⇒ General
body repairs, exterior; Rep. gr. 66 ; Strips / trim panels / ex‐
tensions; Exploded view - heat shield .
– Take out selector mechanism towards rear.
Installing
Tightening torques ⇒ page 39 and ⇒ page 38
Note
Always renew seals, gaskets and self-locking nuts.
– Install tunnel cross member ⇒ page 122 .

– Install heat shield under shift unit ⇒ General body repairs,
exterior; Rep. gr. 66 ; Strips / trim panels / extensions; Explo‐
ded view - heat shield .
– Install propshaft or attach to gearbox ⇒ Rear final drive; Rep.
gr. 39 ; Propshaft; Exploded view - propshaft .
– Install exhaust system and perform stress-free alignment ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .
tion .
– Adjust selector mechanism ⇒ page 48 .
– Install multimedia system operating unit - E380- ⇒ Commu‐
nication; Rep. gr. 91 ; Infotainment system; Removing and
– Install air conditioner operating and display unit ⇒ Heating, air
conditioning; Rep. gr. 87 ; Operating and display unit; Re‐
moving and installing operating and display unit .
1.7 Adjusting selector mechanism

The following are prerequisites for correct gear lever alignment:

Note
♦ Gear selector linkage must be in proper condition and undam‐

aged.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
♦ Gearbox in neutral.
Procedure
– Remove gear knob together with boot ⇒ page 41 .
– Remove ashtray (front) -1- ⇒ General body repairs, interior;
Rep. gr. 68 ; Centre console; Removing and installing ashtray
(front) .
– Remove noise insulation above selector mechanism

⇒ page 42 .
– Check adjustment of push rod: dimension -x-.

• Specification: distance -x- = 25 mm
– If distance measured is not correct, adjust dimension -x- as
follows:
– Loosen bolt -arrow- for push rod.
• The gear lever bearing should move freely in both directions
on slide
– Set dimension -x- by moving gear lever bearing.
– Tighten bolt for push rod -arrow- in that position. Tightening
torque ⇒ Item 7 (page 39)
– Slacken off bolt for selector rod -arrow-.

♦ Connection between selector rod and selector mechanism
should move freely.
Align the gear lever as follows:

– Position bottom of gear lever in centre of gear lever bearing.
• Distance between gear lever bearing and bottom of gear lever
-arrows- must be the same at all points.
– Align gear lever so that it points slightly (3.5°) to the right (as
seen in direction of travel).
– Hold gear lever in this position.

– Tighten bolt for selector rod -arrow-. Tightening torque

Note
The gear lever must remain in the same position while the bolt is
being tightened.
Checking gear lever setting

– Start engine.
– Press clutch pedal.
– Select all gears several times.
– Operate reverse gear detent (press gear lever downwards)
and move gear lever all the way to the left into reverse gear
gate.
– Now move gear lever forwards and engage reverse gear.
Note
Do not exert any sideways pressure on the gear lever while en‐
gaging reverse.
– Check that reverse gear has actually been engaged, and not
1st gear.
• If 1st gear has been engaged instead of reverse, the gear lever
is set too far to the left. Adjust appropriately ⇒ page 50 .
– Move gear lever out of reverse.
– Now engage 2nd gear, but at the same time exert increased
pressure towards the left.
• If the gear lever sticks when engaging 2nd gear, it is set too
far to the right. Adjust appropriately ⇒ page 50 .
Note
♦ It should only be possible to engage reverse gear after over‐

coming the reverse gear detent.
♦ The gear lever should return by itself from the reverse gear
gate to the 3rd/4th gear gate.
♦ If the gear lever sticks or baulks repeatedly when engaging a
gear, perform the adjustment procedure again ⇒ page 50 .
– Install noise insulation ⇒ page 42 .

– Install ashtray (front) ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing ashtray
(front) .
– Install gear knob together with boot ⇒ page 41 .
1.8 Renewing selector shaft oil seal

♦ Extractor tool - T20143/1-
♦ Shock absorber set - T10001/1-
♦ Puller - T40160-
♦ Sealing grease - G 052 128 A1-

Removing
– Engage 1st gear.

– Remove nut -1-.
Note
Caution

– Prise out oil seal with extractor tool - T20143/1- .

• Check selector shaft for damage.
Installing
– Lightly oil outer circumference of oil seal.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in oil seal with -T10001/1- .
• Installation depth: 2 mm below outer edge of housing
– Install gearbox selector lever as follows:

• Gearbox selector lever -2- can only be fitted onto selector shaft
-1- in one position (gap in splines -arrow-).
– Secure gearbox selector lever. Tightening torque
tion .
1.9 Removing and installing gear detector

switch - F208-
• Gearbox installed

♦ Release tool -T40138-
♦ Socket (24 mm) - T40284-
Removing
Note

be damaged.

– Using suitable wire, tie up front exhaust pipe to one side of
rear section of exhaust system (at clamp).

A- .
WARNING
Risk of accident.
left unattended.
– Lower gearbox using engine and gearbox jack - V.A.G 1383

A- only until dimension -a- is reached between tunnel cross
member and body.
• Dimension -a- = 70 mm (minimum)
– Unplug electrical connector -1- for gear detector switch - F208-

using release tool -T40138- and move wiring clear.
Note
Items marked -2- and -3- can be disregarded.
– Unscrew gear detector switch - F208- from selector shaft cov‐

er.

Installing
– Screw gear detector switch - F208- into selector shaft cover.
Tightening torque ⇒ page 57
– Attach connector -2- at gear detector switch - F208- .
Note
Items marked -1- and -3- can be disregarded.
– Tighten bolts -arrows- for tunnel cross member. Tightening

– Assemble exhaust system and perform stress-free alignment
⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - si‐
lencers .
tion .
Tightening torque
Component Nm
Gear detector switch - F208- to gearbox 20
1.9.1 Removing and installing gear detection

sensor - G604-
• Gearbox installed
Removing
Note

be damaged.

– Using suitable wire, tie up front exhaust pipe to one side of
rear section of exhaust system (at clamp).
– Apply lifting column of engine and gearbox jack -V.A.G 1383

A- to gearbox from below (with gearbox support - T10337- at‐
tached).
A- .
WARNING
Risk of accident.
left unattended.


jack - V.A.G 1383 A- .
Different connectors for gear detection sensor - G604-

Unplug electrical connector as follows:
– Press catch -1- downwards and unplug connector -2-.
or
– Use screwdriver to pry out catch -1- approx. 3 mm in direction
of -arrow A-.
– Press catch -1- downwards in direction of -arrow B- and unplug
connector -2-.
– Remove bolt -1- and pull out gear detection sensor - G604-
-3-.
Installing
– Renew O-rings -4-.
Caution
Take care when installing gear detection sensor - G604- : risk

of breakage or sensor malfunction
• Gear detection sensor - G604- -3- must not be knocked
into the gearbox or pulled in by tightening bolt -1-.
• O-rings -4- and bore in gearbox cover must be lubricated
with gear oil.
• Gear detection sensor - G604- -3- can be pushed in care‐
fully using a suitable tool, such as a hammer handle.
– Secure gear detection sensor - G604- with bolt -1-. Tightening

torque ⇒ page 60
– Attach connector -1- and lock in place if necessary.
– Tighten bolts -arrows- for tunnel cross member. Tightening

lencers .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
Tightening torque
Component Nm
Gear detection sensor - G604- 10 + 45°
• Renew bolt

2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 61
⇒ “2.2 Installing gearbox”, page 95
⇒ “2.3 Tightening torques for gearbox”, page 117
2.1 Removing gearbox

⇒ “2.1.1 Removing gearbox - vehicles with 3.0 ltr. TFSI engine”,
page 61
⇒ “2.1.2 Removing gearbox - vehicles with 4.2 ltr. FSI engine”,
page 73
⇒ “2.1.3 Removing gearbox - vehicles with 3.0 ltr. TDI engine”,
page 85
2.1.1 Removing gearbox - vehicles with 3.0 ltr. TFSI engine
Special tools and workshop

equipment required
♦ Support bracket - 10 - 222
A-
♦ Ring spanner insert, 16 mm
- V.A.G 1332/14-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Stepladder - VAS 5085-
♦ Puller - T40160-
2. Removing and installing gearbox 61

♦ Removal lever - 80 - 200-

♦ Counterhold tool - T10172-
with adapters - T10172/5-
♦ Adapter - T40058-
♦ Engine support bracket,
supplementary set -
T40093-
♦ Release tool - T40138-
♦ Articulated wrench, 12 mm
- T40220-
♦ Extractor - T40176-

♦ Engine bung set - VAS 6122-
♦ M8 x 35 bolt and washer (outer ∅ 25 mm)

Removing
Caution
When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
tery.
– Bring front wheels into straight-ahead position.

– Switch off ignition and take out ignition key.
battery .
– Lift off engine cover panels -1- and -2- -arrows-.

– Set up support bracket - 10 - 222 A- with adapter - T40093/6-

on suspension turrets (left and right), as shown in illustration.
– Hook spindles - 10 - 222 A /11- onto engine lifting eyes (left
and right).
– Partly take up weight of engine via the spindles .
– Remove both front wheels.
– Detach noise insulation -1- from wheel housing (both sides).
– Loosen fasteners -1 … 3- and remove noise insulation panels.

Caution
Risk of damage to parts of the running gear.

Do NOT let the vehicle down on the wheels if the subframe,
steering rack or subframe cross brace are not properly instal‐
led.
Do NOT support the vehicle at the subframe or the subframe
cross brace (e.g. with a trolley jack).
– Remove nut -1- for hydraulic line for power steering.

– Remove bolts -arrows- and detach subframe cross brace.
Note
The installation position is shown for a vehicle with dynamic steer‐

ing.
– To remove subframe shield -1- (left and right), unscrew bolts

-arrows- and take out shield towards inside.
– Remove nuts -arrows- securing front silencer (left-side).

– Remove nuts -arrows- securing front silencer (right-side).
Caution
Risk of damage to flexible joint in front silencer.

♦ The flexible joint in the front silencer must not be bent fur‐
ther than 10°.
– Unbolt clamps -1- and -2-, push clamps towards rear and de‐
tach front silencers (left and right).
propshaft.

and -T10172/5- ).


– Unplug electrical connector -2- at engine speed sender - G28-
and move wiring clear.
Note
– Pull cover -1- off bottom of gearbox -arrow-.
– Insert guide stud of adapter - T40058- as follows:

• The larger diameter -arrow 1- faces engine.
• The smaller diameter -arrow 2- faces adapter.
– To slacken bolts securing clutch module to drive plate, coun‐

terhold crankshaft with adapter - T40058- and angled ring
spanner.
Note
When you then turn the crankshaft, only turn crankshaft in direc‐
tion of engine rotation -arrow-.

– Remove 6 bolts -arrow- securing clutch module to drive plate

(turn clutch module by turning crankshaft 60° in direction of
engine rotation each time).
– Remove engine/gearbox securing bolts -7 … 11-.
Caution
Risk of damage to coil connector for airbag.

♦ Front wheels must be in straight-ahead position when uni‐
versal joint is detached from steering rack.
♦ Do not change position of steering wheel or steering rack
after this step (if necessary, fix steering wheel in position
with adhesive tape).
– Remove bolt -arrow- for universal joint ⇒ Running gear, axles,

steering; Rep. gr. 48 ; Steering column; Exploded view -
steering column .
– Press universal joint off steering rack and push all the way up.
Vehicles with hydraulic power steering

– Place used oil collection and extraction unit - V.A.G 1782- be‐
low hydraulic line connection -1- at steering rack.
– Remove bolts -arrows-, detach hydraulic line -1- from steering
rack and place to one side.
Note
Seal off open lines and connections with clean plugs from engine
bung set - VAS 6122- to prevent dirt from entering.


– Remove bolt -1-, press retainer off gearbox and swivel back
towards rear -arrow-.
– Remove bolt -2- and tie up clutch slave cylinder to side in en‐
gine compartment.
Caution
Risk of damage to clutch slave cylinder.

♦ Do not depress clutch pedal after removing clutch slave
cylinder.
– Remove nut -1- for selector rod.
Caution

– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

box support - T40173- underneath gearbox and secure with
tensioning strap -1- as shown in illustration.

– Remove bolts -arrows- on tunnel cross member.
– Lower gearbox initially only by dimension -a- using engine and

gearbox jack - V.A.G 1383 A- .
– Pre-tension spindles - 10 - 222 A /11- on support bracket - 10
- 222 A- slightly.
Note
Use stepladder - VAS 5085- for access to spindles - 10 - 222 A /

11- while vehicle is raised.
– Remove bolt -2- for push rod.

– Remove bolt -3- for connecting rod.
Vehicles with gear detector switch - F208- up to model year 2012
– Disconnect electrical connector -1- for gear detector switch -
F208- using release tool - T40138- and move wiring clear.
Vehicles with gear detection sensor - G604- from model year

2013 onwards
Different connectors for gear detection sensor - G604- ! Unplug
electrical connector as follows:
– Push catch -1- downwards, unplug connector -2- and move
electrical wiring clear.

or
of -arrow A-.
– Push catch -1- downwards in direction of -arrow B-, unplug
connector -2- and move electrical wiring clear.

– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
Note
The installation position is shown with the gearbox removed.
(left-side).
Note
– Unbolt drive shafts (left and right) from flange shafts on gear‐
box -arrows-.

– Remove nuts -arrows- and bolt -1-, press catalytic converter

(right-side) to right side of vehicle and secure.
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ To loosen nuts -arrow- securing catalytic converter -A- to ex‐
haust manifold on right side, use articulated wrench, 12 mm -
T40220- .
♦ Attach a nut loosely to catalytic converter (right-side) to pre‐
vent it from dropping.
– Remove bolt -1- for starter.

– Remove bolt -4-, but do not remove starter.
Note
-Items 2 ... 3- can be disregarded.
– Remove remaining engine/gearbox securing bolts -3 … 6-.

– Detach gearbox from engine and lower carefully using engine
and gearbox jack - V.A.G 1383 A- .
If the removed gearbox is being replaced, the following compo‐
nents must be transferred to the replacement gearbox:

♦ Bracket (both sides) -1- for exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Exploded view - silencers .
♦ Tunnel cross member with gearbox mounting and gearbox
support ⇒ page 122
♦ If necessary, remove clutch module ⇒ Servicing manual gear‐
box; Rep. gr. 30 ; Clutch; Removing and installing clutch
module .
2.1.2 Removing gearbox - vehicles with 4.2 ltr.

FSI engine
Caution
Removing gearbox: Audi A5 with 4.2 ltr. FSI engine

• The gearbox of the Audi A5 with 4.2 ltr. FSI engine up to
vehicle identification number 8T-8A-023117 can only be
removed together with the engine ⇒ Rep. gr. 10 ; Re‐
moving and installing engine; Removing engine .


equipment required
♦ Counterhold tool - T10172-
with adapters - T10172/5-
♦ Puller - T40160-
♦ Articulated wrench, 12 mm
- T40220-
V.A.G 1383 A-

Removing
Caution

tery.

battery .
– Remove engine cover panel -arrows-.

– Loosen wheel bolts of front wheels, but leave wheels in place.
– Raise vehicle.

– Remove bolt -1- for hydraulic fluid pressure line for power
steering.
Caution

led.
– Remove nuts -arrows- securing front silencer (left-side).
– Remove nuts -arrows- securing front silencer (right-side).
Caution
Risk of damage to flexible joint in front silencer.

♦ The flexible joint in the front silencer must not be bent fur‐
ther than 10°.
– Unbolt clamps -1- and -2-, push clamps towards rear and de‐
tach front silencers (left and right).

– Unplug electrical connectors -1- on steering rack and -2- for

engine speed sender - G28- and move electrical wiring clear.
• Engage 6th gear by pulling out selector shaft -1- and shifting
Hold propshaft with counterhold tool - T10172- and adapters -

T10172/5- to prevent it from turning.

– Remove 6 bolts -arrow- for drive plate. To access each bolt,

turn both wheels so that clutch module turns 60° further.
– Remove front wheels.
– If fitted, remove subframe shield -1- (left and right); to do so,

unscrew bolts -arrows- and take out shield towards inside.
– Remove nuts -arrows- and bolt -1- and press catalytic con‐
verter to right side.

Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ To loosen nuts -arrow- securing catalytic converter -A- to ex‐
haust manifold on right side, use articulated wrench, 12 mm -
T40220- .
♦ Attach a nut loosely to catalytic converter (right-side) to pre‐
vent it from dropping.
– Remove coolant pipe (rear) ⇒ Rep. gr. 19 ; Coolant pipes;

Exploded view - coolant pipes .
– Remove air duct -arrow-.
– Unplug electrical connector -1- from air mass meter - G70- .

– Disconnect vacuum line -3- leading to air pipe.
Rest-of-world vehicles:
– Press release tabs and disconnect crankcase breather hose
-2- from air hose.
– Slacken hose clips -4- and release clamps -arrows- to remove
air hose with air mass meter - G70- .
USA vehicles:
Caution
Risk of violating emission legislation applying to USA models.

♦ Do NOT release hose clip -2-.
– Move air hose clear to one side (crankcase breather hose

-2- remains connected). To do so, release hose clips -4- and
clamps -arrows-.

Continued for all vehicles:

– Disconnect vacuum line -1-.
– Detach air cleaner (bottom section) and disconnect electrical
connector -2- at variable intake manifold changeover valve -
N335- on rear of air cleaner.
– Disconnect hose -3- leading to secondary air pump.
– Disconnect coolant hose from radiator -2- and from coolant

pipe (right-side) -1-.
– Remove bolts -1- and -2- and detach coolant hose -arrow-.
– Disconnect coolant pipe (right-side) from connection and
move clear to one side.
– Remove bolts -1- and -2- and detach coolant connection.
Note
-Arrow- can be disregarded.

– Working from above, remove bolt -2- for connecting rod.
Note
– Remove bolts -2 … 6- securing gearbox to engine (accessible

from above).
propshaft.

with adapters - T10172/5- ).


gine compartment.
Caution

♦ Do not depress clutch pedal after removing slave cylinder.
– Remove nut -1-.
Caution

Caution


steering column .
– Remove bolt -1-, press retainer off gearbox and swivel back
towards rear -arrow-.

– Remove bolt -1- for starter.

– Detach starter from gearbox but do not remove starter.



(right-side).
Note
(left-side).
Note
box -arrows-.

Note

If the removed gearbox is being replaced, the following compo‐
nents must be transferred to the replacement gearbox:

♦ Bracket (both sides) -1- for exhaust system ⇒ Rep. gr. 26 ;

Exhaust manifold; Exploded view - exhaust manifold .
♦ Tunnel cross member with gearbox mounting and gearbox
support ⇒ page 122
♦ If necessary, remove clutch module ⇒ Servicing manual gear‐
box; Rep. gr. 30 ; Clutch; Removing and installing clutch
module .
2.1.3 Removing gearbox - vehicles with 3.0 ltr. TDI engine


equipment required
♦ Support bracket - 10 - 222
A-
♦ Rack - 10 - 222 A /1-
♦ Spindle - 10 - 222 A /11-
♦ Ring spanner insert, 16 mm
- V.A.G 1332/14-
V.A.G 1383 A-
♦ Stepladder - VAS 5085-
♦ Puller - T40160-
♦ Counterhold tool - T10172- with adapters - T10172/5-

♦ Adapter - T40058-
Removing
Caution

tery.

battery .

– Remove engine cover panel -arrows-.

– Remove both front wheels.
– Remove front exhaust pipe and particulate filter ⇒ Rep. gr.

26 ; Exhaust pipes/silencers; Exploded view - silencers .

– Working from above, remove bolt -2- for connecting rod.
Note
– Remove bolts -2 … 6- securing gearbox to engine (accessible

from above).
– Set up support bracket - 10 - 222 A- with rack - 10-222 A /1-

and spindle - 10 - 222 A /11- as shown in illustration.
propshaft.


with adapters - T10172/5- ).

– Remove bolt -1- for hydraulic fluid pressure line for power
steering.
Caution

led.
– If fitted, remove subframe shield -1- (left and right); to do so,

unscrew bolts -arrows- and take out shield towards inside.

gine compartment.
Caution

♦ Do not depress clutch pedal after removing slave cylinder.
– Remove nut -1-.
Caution

Caution


steering column .

– Insert guide stud of adapter - T40058- as follows:

• The larger diameter -arrow 1- faces engine.
• The smaller diameter -arrow 2- faces adapter.
– To slacken bolts securing clutch module to drive plate, coun‐

terhold crankshaft with adapter - T40058- at vibration damper.
Note
-Arrow- can be disregarded.
– Remove 6 bolts -arrow- securing clutch module to drive plate

(turn crankshaft 60° in direction of engine rotation each time).
– Remove bolt -1- for starter from engine side.

– Detach starter from gearbox but do not remove starter.



(right-side).
Note
box.

Note
Vehicles with gear detector switch - F208- up to model year 2012

Vehicles with gear detection sensor - G604- from model year

2013 onwards
Different connectors for gear detection sensor - G604- ! Unplug
electrical connector as follows:
– Push catch -1- downwards, unplug connector -2- and move
electrical wiring clear.
or
of -arrow A-.
– Push catch -1- downwards in direction of -arrow B-, unplug
connector -2- and move electrical wiring clear.


– Partly take up weight of engine with spindle - 10 - 222 A /11- .
Note
Use stepladder - VAS 5085- for access to spindle - 10 - 222 A /


2.2 Installing gearbox

⇒ “2.2.1 Installing gearbox - vehicles with 3.0 ltr. TFSI engine”,
page 95
⇒ “2.2.2 Installing gearbox - vehicles with 4.2 ltr. FSI engine”,
page 103
⇒ “2.2.3 Installing gearbox - vehicles with 3.0 ltr. TDI engine”,
page 110
2.2.1 Installing gearbox - vehicles with 3.0 ltr.

TFSI engine
♦ Assembly aid - T40169-
♦ Transportation lock - T40170-

Procedure
Note
♦ Renew bolts which are tightened by turning through a speci‐

fied angle. The aluminium bolts securing the engine to the
gearbox can be used twice only.
fied angle.
♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ 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-instal‐
ling.
♦ Check input shaft of removed gearbox for scoring around
bearing in drive plate -arrow-. Renew needle bearing in drive
plate if necessary ⇒ Rep. gr. 13 ; Cylinder block (gearbox
end); Renewing needle bearing in drive plate .
Tightening torques for installing gearbox: ⇒ page 117
– Check that dowel sleeves -A- for centralising engine/gearbox

are in the cylinder block; install any missing dowel sleeves.
• Check whether aluminium bolts -2 … 11- can be reused for
engine/gearbox connection and mark bolts if necessary
⇒ page 118 .

– If removed previously, install clutch module ⇒ Servicing man‐

ual gearbox; Rep. gr. 30 ; Clutch; Removing and installing
clutch module .
– Position gearbox on gearbox support - T40173- and secure

with tensioning strap -1-, as shown in illustration.
– The following preparations must be made before joining the

engine and gearbox:
– Insert assembly aid - T40169- between gearbox housing and
clutch module from below, as shown in illustration.
• The assembly aid - T40169- must engage in the semi-circular
recess -1- and in the inspection hole -2-.
Note
There is only one inspection hole at the periphery; turn the clutch
module accordingly.
– Insert pin on handle of assembly aid - T40169- into hole in

gearbox housing.

– Insert transportation lock - T40170- into gearbox housing from

below and clamp onto flange shaft -1-.
– Raise gearbox just far enough to be able to insert clutch slave

cylinder.
– Tighten bolt -2-. Tightening torque ⇒ Item 17 (page 20)
Note
-2- is installed.

Caution


– Join gearbox with engine and tighten bolts -3 ... 11-. Tightening
torques ⇒ page 118
– Raise gearbox using engine and gearbox jack - V.A.G 1383

A- initially only until dimension -a- is reached between tunnel
cross member and body.
– Fit starter and tighten bolts -1- and -4-. Tightening torque
⇒ page 118
Note
-Items 2 ... 3- can be disregarded.
– Secure catalytic converter (right-side) ⇒ Rep. gr. 26 ; Exhaust

pipes/silencers; Exploded view - silencers .
– Secure push rod -1- ⇒ Item 27 (page 40) .

– Secure connecting rod -3-. Tightening torque
– Attach electrical connector -2- at gear detector switch - F208-
or gear detection sensor - G604- , and lock in place if neces‐
sary.
– Plug in connector at engine speed sender - G28- .

– Install gearbox selector lever -2- as follows:

– Secure gearbox selector lever -2-. Tightening torque
– Secure drive shafts (left and right) to flange shafts of gearbox

⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft .
– Tighten bolts -arrows- for drive shaft heat shield to 23 Nm.
– Release spindles of support bracket - 10 - 222 A- .

– Raise gearbox further and tighten bolts -arrows- for tunnel
cross member. Tightening torques ⇒ page 122
– Detach engine and gearbox jack - V.A.G 1383 A- with gearbox
support - T40173- from gearbox.
– Remove support bracket - 10 - 222 A- .

lencers .

Tightening sequence – clutch module to drive plate

– Remove assembly aid - T40169- and transportation lock -
T40170- .
– Fit both front wheels.

Note

cant.

Secure clutch module to drive plate as follows:

• Use new bolts.
1332/14- .
– Turn both front wheels so that clutch module/drive plate turns
180° further.
– Now install remaining bolts securing clutch module to drive
plate all round, and tighten immediately to specified torque
(also tighten the first bolt installed) ⇒ Item 3 (page 34) .
– Secure universal joint -arrow- to steering rack ⇒ Running

gear, axles, steering; Rep. gr. 48 ; Steering column; Exploded
view - steering column .
Vehicles with hydraulic power steering

– Install hydraulic lines for power steering ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Hydraulic power steering; Ex‐
ploded view - hydraulic lines, reservoir .
– Install subframe cross brace ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Exploded view - subframe .
– Fill up hydraulic fluid for power steering ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Hydraulic power steering; Check‐
ing power steering fluid level .
– Check gear oil level in gearbox ⇒ page 127 .
– Tighten wheel bolts on both front wheels to specified torque
⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres;
Tightening torque for wheel bolts .
– Observe measures required after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
Caution
Overvoltage can cause irreparable damage to control units.

♦ Do not use charger for boost starting.


FSI engine

Procedure
Note

gaskets.
♦ Hose connections and hoses for charge air system must be
free from oil and grease before fitting.
ling.

⇒ page 119 .

clutch module .



engine and gearbox:
Note
module accordingly.

gearbox housing.



cylinder.
– Tighten bolt -2-. Tightening torque ⇒ Item 17 (page 20)
Note
-2- is installed.

Caution

– Fit starter and tighten bolt -1- from engine side. Tightening
torque ⇒ page 119
– Then tighten bolt -2- from gearbox side to specified torque
⇒ page 119 .

• Dimension -a- = 100 mm (minimum)


– Install heat shield for drive shaft and tighten bolts -arrows- to
23 Nm.
– Secure push rod -1-. Tightening torque ⇒ Item 27 (page 40)

– Attach connector -2- at gear detector switch - F208- .


– Remove engine and gearbox jack - V.A.G 1383 A- and gear‐
box support - T40173- .



T40170- .

Note

cant.


• Use new bolts.
1332/14- .
180° further.

– Secure universal joint to steering rack ⇒ Running gear, axles,
steering column .
– Attach catalytic converter (right-side) to exhaust manifold ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .
– Install front silencers (left and right) ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Removing and installing front silencer .
– Perform stress-free alignment of exhaust system ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Stress-free alignment of exhaust
system .
– Install coolant connection ⇒ Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly .
– Install coolant pipe (right-side) ⇒ Rep. gr. 19 ; Coolant pipes;
Exploded view - coolant pipes .
– Install coolant pipe (rear) ⇒ Rep. gr. 19 ; Coolant pipes; Ex‐
ploded view - coolant pipes .
– Fill up with coolant ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling coolant .
necting battery .
Caution



TDI engine

Procedure
Note

gaskets.
♦ Hose connections and hoses for charge air system must be
free from oil and grease before fitting.
♦ To ensure that the charge air hoses can be connected se‐
curely, you must spray the screws on used screw-type clips
with rust remover prior to installation.
ling.

⇒ page 120 .

clutch module .



engine and gearbox:
Note
module accordingly.

gearbox housing.



cylinder.
– Tighten bolt -2- ⇒ Item 17 (page 20) .
Note
-2- is installed.

Caution

– Fit starter and tighten bolt -1- from engine side. Tightening
torque ⇒ page 119
– Then tighten bolt -2- from gearbox side to specified torque
⇒ page 119 .
– Release spindle -10 - 222 A /11- .
Note
Use stepladder - VAS 5085- for access to spindle - 10 - 222 A /



• Dimension -a- = approx. 70 mm

– Install heat shield for drive shaft and tighten bolts -arrows- to
23 Nm.
– Secure push rod -1- ⇒ Item 27 (page 40) .

– Plug in electrical connector -2- at gear detector switch - F208-
and gear detection sensor - G604- .
– Align connecting rod -3- as illustrated.





T40170- .


Note

cant.

• Use new bolts.
1332/14- .
180° further.

– Secure universal joint -arrow- to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Exploded
view - steering column .
– Install subframe shield (left and right).

– Remove support bracket - 10 - 222 A- .

– Install particulate filter and front exhaust pipe ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Exploded view - silencers .
– Perform stress-free alignment of exhaust system ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Stress-free alignment of exhaust
system .
necting battery .
Caution

2.3 Tightening torques for gearbox
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 %.
Component Nm
Bolts and nuts M6 9
M7 15
M8 20
M10 40
M12 65
Except for the following:

Engine/gearbox attachment (3.0 ltr. TFSI engine)

Item Bolt Nm
1 1) M10 x 50 2) 65
2 1) M12 x 100 3)4) 30 + 90°
3…6 M12 x 100 3)4) 30 + 90°
7 M12 x 125 3)4) 30 + 90°
8, 11 M10 x 60 3)4) 15 + 90°
9, 10 M10 x 95 3)4) 15 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter.
• 2)Property class 10.9; the steel bolt can be re-used any
number of times.
• 3)Audi A4 vehicles up to vehicle identification no.
8K-9-066499, Audi A5 vehicles up to vehicle identification
no. 8T-9-007999: renew aluminium bolts.
• 4) Audi A4 vehicles from vehicle identification no.
8K-9-066500 onwards, Audi A5 vehicles from vehicle iden‐
tification no. 8T-9-008000: aluminium bolts can be used
twice only.
• Checking whether aluminium bolts -2 … 11- can be reused
⇒ page 118 .
Checking whether aluminium bolts -2 … 11- can be reused

♦ Audi A4 vehicles from vehicle identification no. 8K-9-066500
onwards, Audi A5 vehicles from vehicle identification no.
8T-9-008000 onwards: the aluminium bolts (see illustration)
can be used twice only. After they have been used once, an
“X” -arrow- must therefore be chiselled onto the bolts.
♦ To prevent damage to the bolts, they must not be clamped in
a vice when marking them. Clamp a 14 mm socket with 1/2"
drive in the vice instead, and insert the bolt into the socket, as
shown in illustration.
♦ Bolts marked with an “X” must not be used again.
♦ Audi A4 vehicles up to vehicle identification number
8K-9-066499: always renew aluminium bolts.
8T-9-007999: always renew aluminium bolts.
♦ The steel bolt can be re-used any number of times.

Engine/gearbox attachment (4.2 ltr. FSI engine)

Item Bolt Nm
1 1) M10 x 50 2) 65
2 1) M12 x 100 3) 30 + 90°
3…6 M12 x 100 3) 30 + 90°
7 M12 x 175 3) 30 + 90°
8, 11 M10 x 60 3) 15 + 90°
9, 10 M10 x 95 3) 15 + 90°
• 2) Steel bolt - do not renew.
• 3)Check whether aluminium bolts can be reused
⇒ page 119 and renew if necessary.

8T-9-008000 onwards: aluminium bolts can be used twice on‐
ly. After they have been used once, an “X” -arrow- must
therefore be chiselled onto the bolts.
Engine/gearbox attachment (3.0 ltr. TDI engine)
Item Bolt Nm
1 1) M10 x 50 2) 65
2 1) M12 x 100 3) 30 + 90°
3…6 M12 x 100 3) 30 + 90°
7 M12 x 125 3) 30 + 90°
8, 11 M10 x 60 3) 15 + 90°
9, 10 M10 x 95 3) 15 + 90°
• 2) Steel bolt - do not renew.
• 3)Check whether aluminium bolts can be reused
⇒ page 120 and renew if necessary.


8T-9-008000 onwards: aluminium bolts can be used twice on‐
ly. After they have been used once, an “X” -arrow- must
therefore be chiselled onto the bolts.

3 Transporting gearbox
♦ Lifting aid - T40013-
♦ Workshop hoist - VAS 6100-
Procedure
– Insert lifting aid - T40013- in lifting eye on gearbox and secure.
– Engage hook of workshop hoist - VAS 6100- in 3rd notch
-arrow- on lifting aid .
– Lift gearbox with workshop hoist - VAS 6100- and lifting aid -
T40013- .
3. Transporting gearbox 121

4 Assembly mountings
⇒ “4.1 Exploded view - assembly mountings”, page 122
⇒ “4.2 Removing and installing tunnel cross member”,
page 122
⇒ “4.3 Removing and installing gearbox support with gearbox
mounting”, page 124
⇒ “4.4 Removing and installing gearbox mounting”, page 125
4.1 Exploded view - assembly mountings
1 - Nut
❑ 20 Nm
2 - Bolt
❑ 70 Nm
3 - Bolt
❑ 40 Nm
4 - Nut
❑ 20 Nm
5 - Gearbox support
⇒ page 124
6 - Gearbox mounting
⇒ page 125
7 - Stop (bottom)
❑ For gearbox mounting
8 - Bolt
❑ 20 Nm + 90°
❑ Renew
9 - Tunnel cross member
⇒ page 122
4.2 Removing and installing tunnel cross

member

Removing
Proceed as follows:

WARNING
Risk of accident.
left unattended.
4. Assembly mountings 123

– Unscrew nuts -arrows- and remove tunnel cross member.

Installing
• Tightening torques ⇒ page 122
Perform installation in reverse sequence of removal.
4.3 Removing and installing gearbox sup‐

port with gearbox mounting
Removing
– Remove tunnel cross member ⇒ page 122 .
– Remove bolts -arrows- and detach gearbox support from gear‐
box together with gearbox mounting.
Installing
– Secure gearbox support to gearbox together with gearbox
mounting -arrows-. Tightening torque ⇒ Item 3 (page 122)
– Install tunnel cross member ⇒ page 122 .

4.4 Removing and installing gearbox

mounting
Removing
– Remove gearbox support together with gearbox mounting
⇒ page 124 .
– Remove bolts -1- and detach stop -2- (bottom) for gearbox
mounting.
– Remove nut -4- and detach gearbox mounting -5- from gear‐
box support -3-.
Installing
• Tightening torques ⇒ page 122
– Fit gearbox support -3- onto gearbox mounting -5- and tighten
nut -4- hand-tight.
– Secure stop (bottom) -2- with bolts -1-.
– Tighten nut -4-.
– Install gearbox support with gearbox mounting ⇒ page 124 .
4. Assembly mountings 125

5 Dismantling and assembling gearbox

Dismantling and assembling gearbox ⇒ Servicing manual gear‐
box; Rep. gr. 34 ; Dismantling and assembling gearbox

6 Gear oil
⇒ “6.1 Checking gear oil level”, page 127
6.1 Checking gear oil level

Procedure
• The vehicle must be horizontal when checking gear oil level.
– To check gear oil level, unscrew oil filler plug -arrow-.
• Specification: Oil level is correct when gearbox oil is up to low‐
er edge of filler hole.
– Top up with gear oil if necessary. Specifications ⇒ Electronic
parts catalogue
– Screw in oil filler plug.
Tightening torque
Component Nm
Oil filler plug 40
6. Gear oil 127

35 – Gears, shafts
1 Dismantling and assembling gears
and shafts
Dismantling and assembling gears and shafts ⇒ Servicing man‐
ual gearbox; Rep. gr. 35 ; Dismantling and assembling gears and
shafts
128 Rep. gr.35 - Gears, shafts

39 – Final drive - front differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - oil seals”, page 129
⇒ “1.2 Renewing oil seal (right-side)”, page 130
1.1 Overview of fitting locations - oil seals

The oil seals -A- and -B- can only be renewed with the gearbox
removed from the vehicle ⇒ Servicing manual gearbox; Rep. gr.
39 ; Oil seals .
The oil seals -C-, -D- and -E- can be renewed with the gearbox
installed in the vehicle.
Note
If you are renewing the cover for the final drive -item 2-, you must adjust the preload of the tapered roller bearings
for the differential ⇒ page 134 .
A - Oil seal
❑ For input shaft
❑ Renewing ⇒ Servicing
manual gearbox; Rep.
gr. 39 ; Oil seals; Re‐
newing oil seal for input
shaft
B - Oil seal
❑ For flange shaft (left-
side)
❑ Renewing ⇒ Servicing
gr. 39 ; Oil seals; Re‐
newing oil seal (left-
side)
C - Oil seal
❑ For flange shaft (right-
side)
❑ Renewing ⇒ page 130
D - Oil seal
❑ For rear flange shaft or
rear splined shaft
❑ ⇒ “4.4 Renewing oil seal
for flange shaft (rear)”,
page 152
❑ ⇒ “4.3.1 Renewing oil
seal for rear splined
shaft - rear splined shaft
without vibration damp‐
er”, page 147
with vibration damper”,
1. Oil seals 129

page 149
E - Oil seal
❑ For selector shaft
❑ Renewing ⇒ “1.8 Renewing selector shaft oil seal”, page 51
1 - Flange shaft (right-side)
❑ Removing and installing ⇒ “1.2 Renewing oil seal (right-side)”, page 130
2 - Cover for final drive
❑ Renewing ⇒ page 134
3 - O-ring
❑ On cover for final drive
❑ Renewing ⇒ “2.1 Renewing cover for final drive”, page 134
4 - Differential
5 - Gearbox
6 - Rear splined shaft
❑ With vibration damper; for correct version, refer to ⇒ Electronic parts catalogue
❑ Renew oil seal -D- when renewing rear splined shaft
7 - Rear splined shaft
❑ Without vibration damper; for correct version, refer to ⇒ Electronic parts catalogue
❑ Renew oil seal -D- when renewing rear splined shaft
8 - Dust ring
❑ Renew if removed
9 - Flange shaft (rear)
❑ Removing and installing ⇒ “4.4 Renewing oil seal for flange shaft (rear)”, page 152
10 - Flange shaft (left-side)
❑ Removing and installing ⇒ Servicing manual gearbox; Rep. gr. 39 ; Differential; Removing and installing
flange shaft (left-side)
11 - Clutch module
❑ Removing and installing ⇒ Servicing manual gearbox; Rep. gr. 30 ; Clutch; Removing and installing
clutch module
12 - Bolt
❑ 24 Nm
❑ Steel bolts (M8; 38 mm long)
❑ 10x
1.2 Renewing oil seal (right-side)

130 Rep. gr.39 - Final drive - front differential

♦ Drift - VW 295-
♦ Puller - T10037-
♦ Thrust piece - T40163-
♦ Used oil collection and extraction unit - V.A.G 1782-

Removing
• Gearbox is installed.
– Refer to general repair instructions ⇒ page 10 .
– Remove front right wheel.
1. Oil seals 131

– If fitted, remove noise insulation -1- from wheel housing (right-

side).
(right-side).
– Unbolt drive shaft (right-side) from gearbox and place to one
side ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
Place used oil collection and extraction unit - V.A.G 1782- below
gearbox.
– Remove flange shaft (right-side); to do so, secure puller -

T10037- to cover for final drive -arrow-.

– Lever out flange shaft oil seal.
Installing

– Always renew circlip -A- for flange shaft.
– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.
– Lightly oil outer circumference of new oil seal.

– Drive in oil seal onto stop using thrust piece - T40163- . Take
care to keep seal straight when installing.
ing grease - G 052 128 A1- .
– Knock flange shaft in with drift - VW 295- .
– Bolt drive shaft to flange shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Exploded view - drive shaft .
– Fit drive shaft heat shield.
– Checking gear oil level ⇒ page 127
– If fitted, install noise insulation -1- in wheel housing (right-

side).
tion .
Tightening torque
Component Nm
Heat shield for drive shaft to gearbox 23
1. Oil seals 133

2 Final drive
⇒ “2.1 Renewing cover for final drive”, page 134
2.1 Renewing cover for final drive

• When renewing cover for final drive, determine thickness of
new shim to adjust preload of tapered roller bearings for dif‐
ferential.
Note
♦ General repair instructions ⇒ page 10 .

♦ This shim is located behind the tapered roller bearing outer
race in the cover for the final drive.

equipment required
♦ Crankshaft seal installing
tool - VW 204 B-
♦ Drift - VW 295-
♦ Measuring plate -
VW 385/33-
♦ Centring disc - VW 385/41-
♦ Universal dial gauge brack‐
et - VW 387-
♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Hub grease cap puller - VW
637/2-
♦ Wheel bearing tube - 3345-
♦ Puller - T10037-
♦ Ruler - T40100-
• Gearbox is installed.
Procedure
– Refer to general repair instructions ⇒ page 10 .
– Remove front right wheel.
2. Final drive 135

– If fitted, remove noise insulation -1- from wheel housing (right-

side).
low gearbox.
– Unscrew plug -arrow- and drain off gear oil.
– Screw plug -arrow- back in and tighten to 40 Nm.
(right-side).
– Unbolt drive shaft (right-side) from gearbox and place to one
side ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
derneath gearbox below differential.

– Remove flange shaft (right-side); to do so, secure puller -

T10037- to cover for final drive -arrow-.
Unscrew bolts -arrows- and detach cover for final drive.
Caution
Take care not to damage differential.

♦ Make sure differential does not drop out when cover for
final drive is removed.
– Carefully prise tapered roller bearing outer race out of old cov‐
er for final drive; to do so apply hub grease cap puller - VW
637/2- on alternate sides and press in direction of -arrow-.
Note
If the tapered roller bearing outer race cannot be removed with

the hub grease cap puller - VW 637/2- , use internal puller
56 … 110 mm -B- and counter-support -A-.
A - Counter-support , e.g. -Kukko 22/4-

B - Internal puller 56 ... 110 mm , e.g. -Kukko 21/89-
– Remove existing shim.
2. Final drive 137

Determining thickness of shim

– Measure dimension -a- on old cover and new cover as follows:
– Insert centring disc - VW 385/41- in bearing seat for tapered
roller bearing outer race.
– Using digital depth gauge (e.g. digital depth gauge - VAS
6087- ), measure down to joint flange.
Example:
Dimension -a- on old cover for final drive 58.40 mm
Dimension -a- on new cover for final drive 58.65 mm
Difference = 0.25 mm
– Install thicker shim if dimension -a- is smaller on new cover.
– Install thinner shim if dimension -a- is greater on new cover.
Example:
Existing shim 1.50 mm
Difference – 0.25 mm
New shim = 1.25 mm
Note
Select correct shim from ⇒ Electronic parts catalogue .
– The shim thickness in this example is 1.25 mm.

– Install new shim of required thickness in new cover for final
drive.
– Press in tapered roller bearing outer race as far as stop; small‐

er ∅ of -VW 204 B- goes towards tapered roller bearing outer
race.
Note
Support cover for final drive with -3345- directly below bearing
seat.
Check adjustment of preload of tapered roller bearings for differ‐

ential as follows:
– Fit cover for final drive without O-ring and tighten 4 bolts
-arrows-.
– Attach measuring equipment.
– Secure universal dial gauge bracket - VW 387- to threaded
hole in gearbox housing with bolt -A-.
– Apply dial gauge extension to centre of measuring plate -
VW 385/33- .
– Set dial gauge (3 mm measuring range) to »0« with 1 mm
preload.
– Slacken 4 bolts -arrows- by one turn in diagonal sequence.
– Check reading on dial gauge.
• It should be 0.10 ... 0.15 mm.

– Renew O-ring -arrow-.
– Then install cover for final drive with new O-ring and tighten
bolts -arrows-. Tightening torque ⇒ Item 12 (page 130)
Note
Installing new flange shaft oil seal (right-side) ⇒ page 133
– Always renew circlip -A- for flange shaft (right-side).

– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.
– Drive in flange shaft (right-side) with drift - VW 295- .
– Bolt drive shaft to flange shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Exploded view - drive shaft .
– Fit drive shaft heat shield.
– Fill up with gear oil and check gear oil level ⇒ page 127 .
– If fitted, install noise insulation -1- in wheel housing (right-

side).
tion .
Tightening torque
Component Nm
Heat shield for drive shaft to gearbox 23
2. Final drive 139

3 Front differential
Dismantling and assembling differential ⇒ Servicing manual
gearbox; Rep. gr. 39 ; Differential; Dismantling and assembling
differential

4 Centre differential
⇒ “4.1 Exploded view - centre differential housing”, page 141
⇒ “4.2 Removing and installing centre differential housing”, page
142
⇒ “4.3 Renewing oil seal for rear splined shaft”, page 147
⇒ “4.4 Renewing oil seal for flange shaft (rear)”, page 152
4.1 Exploded view - centre differential housing

The centre differential housing can be removed and installed with
the gearbox installed in the vehicle ⇒ page 142 .
1 - Bolt
❑ 24 Nm
❑ Steel bolts
❑ 2x
2 - Centre differential housing
❑ With or without vibration
damper, depending on
design
(with gearbox installed)
⇒ page 142
❑ ⇒ “4.4 Renewing oil seal
for flange shaft (rear)”,
page 152
without vibration damp‐
er”, page 147
with vibration damper”,
page 149
❑ Servicing ⇒ Servicing
gr. 39 ; Centre differen‐
tial
3 - Bolt
❑ 10 Nm + 90°
❑ Aluminium bolts
❑ Always renew
4 - Spring
5 - Dished spring
❑ Installation position: Inner diameter (convex side) faces flange shaft
6 - Shim
7 - Centre differential
❑ Can only be serviced by manufacturer
❑ Renewing bearing for centre differential ⇒ Servicing manual gearbox; Rep. gr. 35 ; Dismantling and
assembling gears and shafts
❑ Removing and installing (with gearbox installed) ⇒ page 142
4. Centre differential 141

8 - Spacer sleeve
9 - Bearing plate
❑ Note correct installation position in relation to gearbox cover ⇒ page 146
10 - Spur gear drive
❑
11 - Gearbox cover / gearbox
4.2 Removing and installing centre differen‐

tial housing
♦ Counterhold tool - T10172- with adapters - T10172/5-

Removing
Note

be damaged.
low gearbox.
– Unscrew plug -arrow- and drain off gear oil.
– Screw plug -arrow- back in and tighten to 40 Nm.

propshaft.

and -T10172/5- ).

WARNING
Risk of accident.
left unattended.


jack - V.A.G 1383 A- .
– Unscrew nuts -arrows- and remove tunnel cross member.

low gearbox.
Caution
Risk of damage to the centre differential.

♦ Pull the centre differential housing slowly and carefully to‐
wards the rear off the gearbox. The centre differential may
otherwise fall out of the gearbox.
♦ A centre differential which has fallen to the ground can no
longer be installed and must therefore be renewed.
– Unscrew bolts -A- and -arrows- securing centre differential

housing -B- to gearbox.
– Carefully pull off centre differential housing -6-, together with

spring -3-, shim -4- and dished spring -5-.
– Detach centre differential -2- and bearing plate -1-.

If bearing plate -1- remains behind in centre differential housing,

proceed as follows:
– Grip one of side ribs on bearing plate -1- with pliers and pull
off in direction of -arrow A-.
– While doing so, carefully tap alternate sides of housing
-arrows B- with a rubber-headed hammer .
Caution
Risk of damage to the sealing surface of the centre differential

housing.
♦ Tap the housing in several places with a hammer.
♦ Take care not to damage sealing surface!
– Remove centre differential.
Installing centre differential and centre differential housing

• Tightening torques
⇒ “4.1 Exploded view - centre differential housing”, page 141
– Thoroughly clean both housing joint surfaces.
Install bearing plate on gearbox as follows:
• Installation position: lug -arrow A- on bearing plate must en‐
gage in slot -arrow B- in gearbox housing.
– Slide on centre differential -2- towards bearing plate -1- as far

as stop.
– Insert dished spring -5-, shim(s) -4- and spring -3- into centre
differential housing -6-.
• Installation position of dished spring -5-: inner diameter (con‐
vex side) -arrow- faces centre differential housing -6-.
– Apply sealing paste - AMV 188 001 02- evenly and not too
thickly.
– Then fit centre differential housing -6- onto gearbox.
– Press centre differential housing -B- fully onto gearbox hous‐

ing and hold in place.
– Fit and tighten new bolts -arrows-. Tightening torque
– Tighten bolts -A-. Tightening torque ⇒ Item 1 (page 141)

– Secure tunnel cross member on gearbox mounting -arrows-.

Tightening torque ⇒ Item 1 (page 122)
– Raise gearbox and tighten bolts -arrows- for tunnel cross

member. Tightening torque ⇒ Item 2 (page 122)

– If fitted, install heat shield for propshaft -A- and tighten bolts
-arrows- to specified torque.
– Fill up with gear oil and check gear oil level ⇒ page 127 .
lencers .
tion .
Tightening torque
Component Nm
Heat shield for propshaft to centre differential 25
housing
4.3 Renewing oil seal for rear splined shaft

⇒ “4.3.1 Renewing oil seal for rear splined shaft - rear splined
shaft without vibration damper”, page 147
⇒ “4.3.2 Renewing oil seal for rear splined shaft - rear splined
shaft with vibration damper”, page 149
4.3.1 Renewing oil seal for rear splined shaft

- rear splined shaft without vibration
damper

♦ Extractor tool - T20143-
♦ Assembly tool - T40239-

Procedure
– Pry off dust ring -1-.
Note
The dust ring cannot be removed without being damaged.
– Pull out oil seal for rear splined shaft.

– Clean contact surface and sealing surface.
– Lightly lubricate outer circumference of oil seal with gear oil.

– Fit guide sleeve - T40239/1- -item 1- onto rear splined shaft.

ing grease - G 052 128 A1- .
– Push oil seal -2- over guide sleeve -item 1- and onto rear
splined shaft.
• Installation position: the open side of the seal should face the
gearbox housing.
– Drive in oil seal as far as stop using thrust piece - T40239- ,

-item 1- of assembly tool - T40239- . Make sure oil seal re‐
mains straight.
Note
Pull guide sleeve - T40239/1- carefully out of oil seal so that seal‐
ing lip is not rolled back.
– Clip on new dust ring -1-.

– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Exploded view - propshaft .
– Checking gear oil level ⇒ page 127
4.3.2 Renewing oil seal for rear splined shaft

- rear splined shaft with vibration damp‐
er

♦ Drift sleeve - 30 - 100-
♦ Extractor tool - T20143-
♦ Assembly tool - T40239-

Procedure
– Remove centre differential housing ⇒ page 142 .
– Remove circlip -arrow- on inside of housing.
Note
The circlip locates the rear splined shaft on the bearing in the
housing.
– Carefully knock rear splined shaft out of centre differential

housing using copper drift.
Note
In order to drive out the rear splined shaft, clamp the centre dif‐
ferential housing in a vice or have a second mechanic hold it as
required.
– Lever out oil seal -1-.
Note
Installing oil seal

– Lightly lubricate outer circumference of oil seal with gear oil.
• Installation position: the open side of the oil seal faces the
housing.
– Drive in oil seal as far as stop using thrust piece , -item 1- of
assembly tool - T40239- . Make sure oil seal remains straight.
ing grease - G 052 128 A1- .
– Press rear splined shaft into centre differential housing as fol‐

lows:
– Insert rear splined shaft into centre differential housing from
below.
– Place housing with rear splined shaft on thrust plate - VW 402-
under workshop press.
– Position drift sleeve - 30 - 100- on inner race of ball bearing.
– Press in rear splined shaft.

– Fit circlip -arrow- into groove on rear splined shaft.

– Install centre differential housing ⇒ page 146 .
4.4 Renewing oil seal for flange shaft (rear)


♦ Drift sleeve - 30 - 100-
♦ Thrust piece - T40165-
Remove centre differential housing -B- ⇒ page 142 .
Remove circlip -arrow-.

Press out flange shaft.

– Position centre differential housing in such a way that the
flange shaft does not make contact with thrust plates - VW
401- and -VW 402- when it is pressed out.
Lever out oil seal -1-.
Note
Installing oil seal

Lightly lubricate outer circumference of oil seal and drive in onto
stop. Make sure oil seal remains straight.
ing grease - G 052 128 A1- .
Press in flange shaft.

• Ball bearing for flange shaft must be installed.
• When pressing in, drift sleeve - 30 - 100- must press against
inner race of ball bearing.

– Fit circlip onto flange shaft -arrow-.

– Install centre differential and centre differential housing
⇒ page 146 .

6-Speed Manual Gearbox 0B4 Four-Wheel Drive

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6-Speed Manual Gearbox 0B4 Four-Wheel Drive

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Service

6-speed manual gearbox 0B4, four-wheel drive

Service Department. Technical Information

5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1.1 Gearbox identification

-Arrow 1- gearbox code letters and consecutive serial number

1.2 Identification of final drive

1.2.1 Identification of final drive - rear final

♦ Code letters, allocation, ratio, capacities ⇒ Rear final drive;

Location on final drive

Final drive 0BC -arrow- and 0AR

♦ The designation “0AR” always appears on the rear final drive

Code letters and date of manufacture for rear final drive

When installing a new rear final drive unit, it is important to verify

2 Rep. gr.00 - Technical data

1.2.2 Identification of final drive - rear final

♦ Code letters, allocation, ratio, capacities ⇒ Rear final drive;

Location on rear final drive

♦ -Arrow 1- Code letters -LFW-

When installing a new rear final drive unit, it is important to verify

2.1 Allocation of gearbox to engine

2.1.1 Allocation of gearbox to engine - Audi A4

Manual gearbox 6-speed 0B4, four-wheel drive

4 Rep. gr.00 - Technical data

Manual gearbox 6-speed 0B4, four-wheel drive

Manual gearbox 6-speed 0B4, four-wheel drive

Manual gearbox 6-speed 0B4, four-wheel drive

Manual gearbox 6-speed 0B4, four-wheel drive

2.1.2 Allocation of gearbox to engine, Audi A5

Manual gearbox 6-speed 0B4, four-wheel drive

6 Rep. gr.00 - Technical data

Manual gearbox 6-speed 0B4, four-wheel drive

Manual gearbox 6-speed 0B4, four-wheel drive

2.1.3 Allocation of gearbox to engine - Audi A5

Manual gearbox 6-speed 0B4, four-wheel drive

8 Rep. gr.00 - Technical data

3.1 Transmission layout - four-wheel drive

-Arrows- point in direction of travel.

4.1 General repair instructions

10 Rep. gr.00 - Technical data

O-rings, seals, oil seals and gaskets

12 Rep. gr.00 - Technical data

5.1 Overview of fitting locations - electrical

Gear detection sensor - G604- item -1-

14 Rep. gr.00 - Technical data

1.1 Exploded view - pedal cluster

1.1.1 Exploded view - pedal cluster, LHD ve‐

1.1.2 Exploded view - pedal cluster, RHD ve‐

16 Rep. gr.30 - Clutch

Installing over-centre spring

• “II” -arrow B- ♦ Not used on vehicles with »0B4

– Insert over-centre spring with assembly clip - T40025- .

18 Rep. gr.30 - Clutch

1.2 Exploded view - clutch hydraulics

1 - Clutch slave cylinder

A one-piece pipe/hose assembly

11 - Clutch master cylinder