Controls, Housing (Manual Transmission 0b2 (coupe)) Audi A5 I

TRANSMISSION FLUID LEVEL, CHECKING

Procedure

Note. The vehicle must be level when checking the transmission fluid level.

If equipped, remove rear noise insulation -2-. Refer to Description and Operation .

Scheme 104

Remove the transmission fluid filler plug -arrow- to check transmission oil.

Scheme 105

1. Specified value: The level is correct when the transmission fluid comes up to the bottom edge of oil filler hole.

Add transmission fluid, if necessary. Specification, refer to CODE LETTERS, TRANSMISSION ALLOCATION, RATIOS AND CAPACITIES .

Install the transmission fluid filler plug.

Tightening Specifications

GEARSHIFT MECHANISM OVERVIEW

Arrow A- gearshift lever movement

Arrow B- selector lever movement

Scheme 106

1. Connecting Rod
2. Push Rod
3. Gearshift Rod
4. Gearshift Lever

Scheme 107

1. Gearshift Knob With shift lever boot Removing and installing, refer to «SHIFT KNOB WITH SHIFT LEVER BOOT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__shift-knob-with-shift-lever-boot)
2. Clamp Secures the shift lever knob to the shift lever. Attach using hose clamp pliers V.A.G 1275
3. Boot Available only together with the support ring -item 4- 4 . Remove and install together with the noise insulation -item 5- 5 «NOISE INSULATION»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe)
4. Support Ring Available only together with the boot -item 3- 3
5. Noise Insulation Removing and installing, refer to «NOISE INSULATION»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe)
6. Gasket
7. Nut 8 Nm
8. Mount For the shift lever support
9. Shift Lever with Shift Lever Support

Scheme 108

1. Locking Ring Remove ball when removing
2. Spacer
3. Pressure Spring
4. Ball Guide Do not lubricate
5. Ball Do not lubricate
6. Insulation For the shift lever support -11- 11 Do not lubricate
7. Bolt 23 Nm
8. Clamping Plate Do not lubricate
9. Selector Lever Offset faces toward rear Lubricate the tip-pressure guide and shift lever contact surfaces; grease, Grease the contact surfaces for the joint -12- 12; Grease
10. Spacer Tube Grease the outer circumference; grease
11. Shift Lever Support Removing and installing, refer to «SELECTOR MECHANISM»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__selector-mechanism). Do not lubricate
12. Joint Piece Between the selector rod and shift lever Grease the contact surfaces for the shift lever; Grease
13. Bolt For the joint piece -12- 12
14. Bolt 23 Nm
15. Nut 10 Nm
16. Gearshift Rod
17. Push Rod With screw and washers
18. Nut 20 Nm Replace
19. Bolt 4 Nm
20. Gearshift Lever CAUTION: Danger of causing damage to the gearshift shaft inside the transmission. Do not pry the transmission shift lever off using a pry bar or hit it with a hammer. The only tool that is allowed to be used to pull the transmission shift lever off is the puller for gear shaft linkage T40160. Removing (Scheme 109)Insert so that master spline aligns with shift rod
21. Sealing Boot
22. Ball Socket Grease the bearing area for the transmission shift lever -20- 20 as needed; Grease
23. Bearing Bushing To remove, remove clip -26- 26
24. Connecting Rod To remove, remove clip -26- 26
25. Bolt 20 Nm
26. Clip
27. Bolt 20 Nm

Scheme 109

Install the T40160 and remove the transmission shift lever -1-.

SELECTOR MECHANISM, ADJUSTING

The following is important to make sure the gearshift adjustment is correct

Note. Operating and transfer elements of shift mechanism must be in proper condition. Shift mechanism must move freely. The transmission, clutch and clutch mechanism must also be in proper condition. Transmission in neutral.

Procedure

Scheme 110

Remove shift knob with cover. Refer to SHIFT KNOB WITH SHIFT LEVER BOOT .

Remove the front ashtray -1-. Refer to Removal and Installation .

Remove the noise insulation over the shift mechanism. Refer to NOISE INSULATION .

Scheme 111

Check adjustment on the push rod (dimension -x-).

Scheme 112

1. Specified value: -x- = 25 mm

If this is not the case, adjust distance -x- as follows

Loosen the push rod bolt -arrow-.

1. You must be able to move shift lever support back and forth lightly on sliding piece.

Adjust -x- by moving the selector lever bearing.

Tighten the push rod bolt -arrow- in this position. Tightening specification; refer to item 7 .

Loosen the push rod bolt -arrow-.

Scheme 113

1. The connection of selector rod to selector mechanism must move freely.

Align Shift Lever as Follows

Scheme 114

Center bottom of shift lever in middle of shift lever support.

1. Distance from shift lever support to bottom of shift lever -arrows- must be equal at all places.

Align shift lever so that it points in direction of travel and faces only very slightly (3.5°) toward right.

Scheme 115

Hold shift lever in this position.

Tighten the push rod bolt -arrow-. Tightening specification -item 14- 14 .

Note. Shift lever position must not change after tightening the bolt.

Checking Gearshift Lever Adjustment

Start the engine.

Press the clutch.

Shift through all the gears several times.

Operate reverse gear lock (push shift lever down) and move shift lever all the way left in reverse gear gate.

Then push shift lever forward in reverse gear.

Note. You must not exert any left or right force on shift lever when doing this.

Check whether the reverse gear and not 1st gear was selected.

1. If 1st gear was selected instead of reverse gear, shift lever is too far left. Correct adjustment «SELECTOR MECHANISM, ADJUSTING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__selector-mechanism-adjusting) .

Take out of reverse gear.

Now, with greater side force toward left on shift lever, shift into 2nd gear.

1. If shift lever catches when engaging 2nd gear, shift lever is too far right. Correct adjustment «SELECTOR MECHANISM, ADJUSTING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__selector-mechanism-adjusting) .

Note. You must only be able to shift into reverse gear after activating reverse gear lock. The shift lever must move from the reverse gear gate into the 3rd/4th gear selector lever gate on its own. Should a gear fail to engage smoothly after repeated selection, then repeat the selector adjustment SELECTOR MECHANISM, ADJUSTING .

Install the noise insulation cover. Refer to NOISE INSULATION .

Install the front ashtray. Refer to Removal and Installation .

Install the shift knob with cover SHIFT KNOB WITH SHIFT LEVER BOOT .

Scheme 116

1. Nut 20 Nm
2. Bolt 70 Nm
3. Bolt 40 Nm
4. Nut 20 Nm
5. Transmission Support Removing and installing, refer to «TRANSMISSION SUPPORT WITH TRANSMISSION MOUNT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe)
6. Transmission Mount Removing and installing, refer to «TRANSMISSION MOUNT»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe)
7. Lower stop For the transmission mount
8. Bolt 20 Nm + 90° turn Replace
9. Tunnel Crossmember Removing and installing, refer to «TUNNEL CROSSMEMBER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__tunnel-crossmember) .

FASTENER TIGHTENING SPECIFICATIONS

Drive Axle Heat Shield - Tightening Specification

Scheme 117

Tighten the heat shield bolts -arrows- to 23 Nm.

Securing the 2.0L TFSI Engine to the Manual Transmission

Scheme 118

Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.

Securing the 3.2L FSI Engine to the Manual Transmission

Scheme 119

Scheme 120

1. Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.
2. Bolts marked with an "X" may not be used again.
3. Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.
4. Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.

SHIFT KNOB WITH SHIFT LEVER BOOT

Note. The gearshift knob is removed together with the gearshift lever boot.

Special tools and workshop equipment required

1. Trim Removal Wedge 3409
2. Hose Clamp Pliers V.A.G 1275

Scheme 121

Remove the gearshift lever boot using the 3409 -arrows-.

Fold the shift lever boot up and over the shift lever knob.

Scheme 122

Open the clamp -arrow- and remove the gearshift lever knob with the shift lever boot.

INSTALLING

Install in reverse order of removal. Note the following

Secure the clamp -arrow- using the V.A.G 1275.

REMOVING

Turn off the ignition.

Remove the shift lever knob with the shift lever boot. Refer to SHIFT KNOB WITH SHIFT LEVER BOOT .

Remove the multimedia system control head -E380-. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Scheme 123

Release the tabs -1- in direction of -arrow-. Raise the rear noise insulation when doing this.

Pull the noise insulation off the tabs -3-.

Pull the boot -2- off the gearshift lever in direction of -arrow-.

Scheme 124

Mount the noise insulation on the tabs -1- and then push down on it until the tabs -2- lock.

Stretch the boot over the shift lever into the rounded groove -arrow A-.

Press the support ring into the boot over the shift lever support in the direction of -arrow B- as far as the stop.

Install in reverse order of removal. Note the following

Install the multimedia system control head -E380-. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Install the shift lever knob with the shift lever boot. Refer to SHIFT KNOB WITH SHIFT LEVER BOOT .

SELECTOR MECHANISM

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
3. Gearbox Support T10337
4. Puller for Gear Shaft Linkage T40160

Scheme 125

Turn off the ignition.

Remove the shift lever knob with the shift lever boot. Refer to SHIFT KNOB WITH SHIFT LEVER BOOT .

Remove the Air Conditioning (A/C) system control head. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Remove the multimedia system control head -E380-. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Scheme 126

Remove the front ashtray -1-. Refer to Removal and Installation .

Remove the noise insulation over the shift mechanism. Refer to NOISE INSULATION .

Scheme 127

Remove nuts -arrows-.

Remove the rear noise insulation -2-. Refer to Description and Operation .

Scheme 128

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.

Disconnect the exhaust system at clamping sleeve(s) -arrows-.

Scheme 129

Remove the bolts -arrows- and remove the driveshaft heat shield -1-.

Scheme 130

Driveshaft Bolted on the Transmission Side

Scheme 131

Remove the bolts that connect the driveshaft to the transmission by counter holding them with the T10172 and T10172/5.

Press the driveshaft together with the rear final drive; the universal joint is able to slide axially.

Secure the driveshaft to the side.

Driveshaft Connected on the Transmission Side

Remove the driveshaft. Refer to Removal and Installation or Removal and Installation .

All Vehicles

Scheme 132

Remove the bolts -4- and remove the crossbrace -3-.

Remove the nuts -1- and remove the heat shield -2-.

Support the transmission using the V.A.G 1383 A with the T10337 attached.

Scheme 133

Lift the transmission slightly using the V.A.G 1383 A.

Remove the bolts from the tunnel crossmember -arrows-.

Scheme 134

Lower the transmission to dimension -a- using the V.A.G 1383 A.

Scheme 135

1. Dimension -a- = maximum 80 mm.

Remove the bolt -1- from the push rod and the -3- connecting rod.

Scheme 136

Note. Ignore -2-.

Remove the nut -1-.

Scheme 137

Note. Ignore -2-.

Install the T40160 and remove the transmission shift lever -1-.

Remove the heat shield underneath the gearshift mechanism. Refer to Removal and Installation .

Remove the shift mechanism downward.

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «SELECTOR MECHANISM OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) and «GEARSHIFT KNOB WITH GEARSHIFT LEVER BOOT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Note. Seals and self-locking nuts must be replaced.

Install the tunnel crossmember. Refer to TUNNEL CROSSMEMBER .

Install the heat shield under the shift mechanism. Refer to Removal and Installation .

Secure the driveshaft on the transmission. Refer to Removal and Installation or Removal and Installation .

Reconnect exhaust system making sure it is not under stress. Refer to [For engine(s) CALA] Removal and Installation .

Install the noise insulation. Refer to Description and Operation .

Install the gearshift mechanism. Refer to SELECTOR MECHANISM, ADJUSTING .

Install the multimedia system control head --. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Install the A/C system control head. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

TRANSMISSION, REMOVING

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Engine Support Adapter 10 - 222 A /3
3. Spindle 10 - 222 A /11
4. Ring Spanner Insert AF16 V.A.G 1332/14
5. Engine-/Gearbox Jack V.A.G 1383 A
6. Step Ladder VAS 5085
7. Puller for Gear Shaft Linkage T40160
8. Gearbox Support T40173
9. Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
10. Release Tool f/ Rev. Light Switch Conn. T40138
11. 2 x Hose Clamps Up to 25 mm in Dia. 3094
12. Hose Clip Pliers V.A.G 1921

Removing

Scheme 138

Turn off the ignition and remove the key.

Disconnect the battery Removal and Installation .

Carefully remove the engine cover from the pins in the direction of the -arrow-. Do not pull sharply on the engine cover or pull it to one side.

Scheme 139

Position the 10 - 222 A with the 10 - 222 A /3 on the left and right suspension strut towers as illustrated.

Scheme 140

Engage the 10 - 222 A /11 on the engine lifting eyes.

Loosen the fasteners -1 through 4- and -arrows- and remove the noise insulation.

Scheme 141

Remove the subframe crossbrace. Refer to Removal and Installation

Scheme 142

Remove the steering intermediate shaft from the steering gear and push it upward. Refer to Description and Operation .

Scheme 143

Vehicles with Transmission Fluid Heater

Scheme 144

Remove both of the coolant hoses from the transmission with 3094.

Place the drip tray underneath the transmission, open the spring clamps -1- and remove both of the coolant hoses.

All Vehicles

Scheme 145

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.

Disconnect exhaust system at the double clamp -arrow-.

Secure the front exhaust pipe on the heat shield under the shift mechanism with wire.

Remove the bolt -1- and tilt the catalytic converter bracket to the right.

Scheme 146

Note. Ignore the nuts -arrows-.

Remove the bolts -arrows- and remove the driveshaft heat shield (if equipped) for the driveshaft -A-.

Scheme 147

Block the driveshaft using the T10172 and T10172/5 so that it does not turn, too.

Note. For vehicles with "the driveshaft connected on the transmission side", the rear final drive is counter held the same way.

Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in direction of -arrow- into 6th gear.

Scheme 148

Remove the lower cover -1- from the transmission -arrow-.

Scheme 149

Turn the clutch module over both front wheel 120° in direction of engine rotation and remove the three drive plate bolts -arrow-.

Scheme 150

Driveshaft Bolted on the Transmission Side

Remove the bolts that connect the driveshaft to the transmission by counter holding them with the T10172 and T10172/5.

Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

Secure the driveshaft to the side.

Driveshaft Connected on the Transmission Side

Remove the driveshaft. Refer to Removal and Installation or Removal and Installation .

All Vehicles

Scheme 151

Remove the bolts -arrows- and then remove the heat shield inward to remove the subframe shield -1- on the left and right.

Remove the bolts -arrows- and then remove the heat shield from the right drive axle.

Remove left and right drive axles from transmission flange shafts.

Scheme 152

Disconnect the connector from the transmission neutral position sensor -G701- -1- and free up the cable.

Scheme 153

Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Remove the nut -1-.

Mount the T40160 and remove the gearshift rod -1-.

Remove the engine/transmission connecting bolts -8 to 11-.

Note. The bolts -1 through 7- connecting the engine to the transmission are removed and installed from below with the transmission lowered.

Position the V.A.G 1383 A and the T40173 under the transmission and secure it with the tensioning strap -1- as illustrated.

Scheme 154

Note. Be careful not to get the electrical wires caught on the transmission when attaching the tensioning strap.

Remove the bolts from the tunnel crossmember -arrows-.

Lower the transmission using the V.A.G 1383 A first to dimension -a-.

1. Dimension -a- = maximum 80 mm.

Slightly pretension the threaded spindles on the 10 - 222 A.

Note. Use a VAS 5085 to get to the threaded spindles when the vehicle is raised.

Disconnect the connector -1- from the transmission range gear recognition switch -F208- or the gear recognition sensor -G604- with the release tool T40138 and free up the wires.

Scheme 155

Remove the push rod bolt -2-.

Remove the connecting rod bolt -3-.

Remove the starter bolt -3- from the engine side.

Scheme 156

Remove the bolt -1-.

Remove the spacer sleeve -2- between the starter and the transmission.

Remove the starter from the transmission and leave it in the installation position.

Note. It is not necessary to disconnect the starter cable.

Remove all remaining engine/transmission bolts.

Press the transmission off the engine and lower it carefully using the V.A.G 1383 A.

If the transmission removed is being replaced, then the following components must be changed

Scheme 157

Scheme 158

1. Bracket -1- for the exhaust system straps. Refer to «Removal and Installation»(ref-520115-S25236911462012123100000) .
2. Tunnel crossmember with the transmission mount and transmission support. Refer to «TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .
3. Removing the clutch module if necessary. Refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009)

TRANSMISSION, INSTALLING

Special tools and workshop equipment required

1. Assembly Aid T40169
2. Transportation Lock T40170
3. Gearbox Support T40173
4. Spindles 10 - 222 A /11
5. Ring Spanner Insert AF16 V.A.G 1332/14
6. Hose Clamps Up to 25 mm in Dia. 3094

Procedure

Note. Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times. Replace self-locking nuts and bolts and seals, gaskets and O-rings. Secure all hose connections with hose clamps of the same type as those equipped by the factory, When installing, bring all cable ties back to the same positions.

Transmission installation tightening specifications TRANSMISSION, INSTALLING .

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

Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate if necessary. Refer to Removal and Installation .

Scheme 159

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

1. See if it is possible to use the aluminum bolts -2 through 11- again and mark them if necessary. «TRANSMISSION, INSTALLING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe__transmission-installing) .

Installing the clutch module if necessary. Refer to Removal and Installation .

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

Scheme 160

Insert the T40169 in the transmission housing and the clutch module from below as shown in the illustration.

1. The T40169 must engage in the semi-circular opening -1- and into the check hole -2-.

Note. There is only 1 inspection opening on the circumference. Rotate the clutch module as needed.

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

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

Scheme 161

Raise the transmission straight up until the clutch slave cylinder -1- can be inserted.

Scheme 162

Tighten bolt -2-. Tightening specification -item 17- CLUTCH HYDRAULICS OVERVIEW .

Note. The next step is only necessary if a drive plate with alignment pins -2- is installed.

Align the drive plate to the clutch module so the alignment pins -2- on the drive plate (if applicable) can engage in the larger holes -1- on the clutch module.

Connect the transmission to the engine and tighten -3.... 11- the bolts. Tightening specifications TRANSMISSION, INSTALLING .

Insert the starter and tighten the bolt -3- manually from the engine side out.

Install the spacer sleeve -2- between the starter and transmission, push the bolt -1- through and tighten.

Tighten the starter bolts -1 and 3-. Tightening specifications TRANSMISSION, INSTALLING .

Raise the transmission using the V.A.G 1383 A until dimension -a- is reached between the subframe and the body.

1. a- = minimum 80 mm

Attach the push rod -1- -item 27- 27 .

Attach the connecting rod -3-. Tightening specification -item 25- 25 .

Connect the connector -2- to the transmission range gear recognition switch -F208- or the gear recognition sensor -G604-.

Install the transmission shift lever -2- as follows

Scheme 163

1. The gearshift lever -2- can be attached to the gearshift shaft -1- in only one position (gap in the splines -arrow-).

Tighten the selector lever. Tightening specification -item 18- 18 .

Connect the connector to the transmission neutral position sensor -G701- -1-.

Loosen the 10 - 222 A /11.

Lift the transmission further and tighten the bolts -arrows- on the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Remove the V.A.G 1383 A and T40173.

Attach the left and right drive axles to the transmission flange shafts. Refer to Removal and Installation .

Install the driveshaft heat shield. see scheme 94

Install the subframe shield on the left and right side.

Secure the driveshaft on the transmission. Refer to Removal and Installation or Removal and Installation .

Block the driveshaft. To do this, place the T10172 and T10172/5 on the driveshaft bolts on the transmission or the rear final drive.

Tightening Sequence - Clutch Module to the Drive Plate

Remove the T40169 and T40170.

Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in direction of -arrow- into 6th gear.

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

Turn both front wheel together in one direction until the clutch module turns one complete turn (360°).

1. The check hole -arrow- must be visible in the transmission housing cut-out.

Tighten the clutch module to the drive plate as follows

1. Use new bolts.
2. Tightening specification -item 3- «CLUTCH MODULE OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-022012__clutch-module-overview) .
3. Tighten the bolts using the V.A.G 1332/14.

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

Rotate the clutch module 120° further in the direction of engine rotation with the front wheels and install the second bold and tighten by hand (2 Nm).

Rotate the clutch module 120° in the direction of engine rotation again.

Install the third bolt and tighten it. Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Tighten the remaining two bolts. Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Install in reverse order of removal. Note the following

Install the driveshaft heat shield -A- and tighten the bolts -arrows- to 25 Nm, if equipped.

Install the exhaust system so that it is free of tension. Refer to Removal and Installation .

Vehicles with Transmission Fluid Heater

Connect the coolant hoses to the connections on the transmission and secure them with the spring clamps -1-.

Remove the 3094.

Fill with coolant. Refer to General Information .

All Vehicles

Attach the steering intermediate shaft to the steering gear. Refer to Description and Operation .

Install the subframe crossbrace. Refer to Removal and Installation .

Gear oil level in manual transmission, checking. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

Install the noise insulation. Refer to Description and Operation .

Complete the steps required after connecting the battery. Refer to Removal and Installation .

Tightening Specifications

Note. The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant. Do not use any ungreased parts. Tightening specification tolerance +/- 15%.

Tighten the heat shield bolts -arrows- to 23 Nm.

Securing the Engine to the Manual Transmission

1. Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.
2. Bolts marked with an "X" may not be used again.
3. Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.
4. Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Engine Support Adapter 10 - 222 A /3
3. Spindle 10 - 222 A /11
4. Ring Spanner Insert AF16 V.A.G 1332/14
5. Engine-/Gearbox Jack V.A.G 1383 A
6. Step Ladder VAS 5085
7. Puller for Gear Shaft Linkage T40160
8. Gearbox Support T40173
9. Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
10. Release Tool f/ Rev. Light Switch Conn. T40138
11. Pry Lever - Rmv Outside Mirror 80 - 200
12. Engine Support Basic Set T40091
13. Engine Support Supplement Set T40093
14. Connector T40091/3

Removing

Turn off the ignition and remove the key.

Disconnect the battery. Refer to Removal and Installation .

Remove the rear engine cover -arrows-.

Scheme 164

Remove the left and right front wheels.

Remove the left and right noise insulation -1- inside the wheel housing.

Scheme 165

Loosen the fasteners -1, 2, 3 and 4- and remove the noise insulation.

Scheme 166

Remove the subframe crossbrace. Refer to Removal and Installation .

Remove the steering intermediate shaft from the steering gear and push it upward. Refer to Description and Operation .

Remove the left and right front muffler. Refer to Removal and Installation .

Remove the bulkhead plenum chamber. Refer to Removal and Installation .

Remove the nuts -arrows- and the bolt -1- and push the catalytic converter to the right side.

Note. The illustration shows the installation position with the engine removed.

Remove the bolts -2 through 6- connecting the engine to the transmission. They are accessible from above.

Secure the right catalytic converter loosely using a nut so it does not fall down.

Position the 10 - 222 A with T40091/3 on the left and right suspension strut towers as shown in the illustration.

Scheme 167

Engage the 10 - 222 A /11 in the right engine lifting eye.

Install the additional 10 - 222 A parts as illustrated. Place the T40093/3 on the notches in the longitudinal member.

Scheme 168

Engage the 10 - 222 A /11 in the left front engine lifting eye.

Disconnect the connector -2- from the Engine Speed (RPM) sensor -G28- and free up the wire.

Scheme 169

Note. Ignore -1-.

Remove the bolts -arrows- and remove the driveshaft heat shield (if equipped) for the driveshaft -A-.

Block the driveshaft using the T10172 and T10172/5 so that it does not turn, too.

Note. For vehicles with "the driveshaft connected on the transmission side", the rear final drive is counter held the same way.

Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in direction of -arrow- into 6th gear.

Remove the lower cover -1- from the transmission -arrow-.

Turn the clutch module over both front wheel 60° in direction of engine rotation and remove the six drive plate bolts -arrow-.

Driveshaft Bolted on the Transmission Side

Remove the bolts that connect the driveshaft to the transmission by counter holding them with the T10172 and T10172/5.

Press the driveshaft together with the rear final drive; the universal joint is able to slide axially.

Secure the driveshaft to the side.

Driveshaft Connected on the Transmission Side

Remove the driveshaft. Refer to Removal and Installation or Removal and Installation .

All Vehicles

Remove the bolts -arrows- and then remove the heat shield from the right drive axles.

Note. The illustration shows the installation position with the transmission removed.

Remove the bolts -arrows- and the left drive axle heat shield.

Scheme 170

Note. The illustration shows the installation position with the transmission removed.

Remove left and right drive axles from transmission flange shafts.

Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Remove the nut -1-.

Mount the T40160 and remove the gearshift rod -1-.

Remove the bolt -1- press the retaining tab off the transmission and tilt it back -arrow-.

Scheme 171

Position the V.A.G 1383 A and the T40173 under the transmission and secure it with the tensioning strap -1- as illustrated.

Remove the starter bolt -4- from the engine side.

Scheme 172

Remove the starter from the transmission and leave it in the installation position.

Note. The starter cables -2 and 3- do not need to be loosened. Ignore -1-.

Remove the remaining bolts -7 through 11- that attach the engine to the transmission.

Remove the bolts from the tunnel crossmember -arrows-.

Lower the transmission using the V.A.G 1383 A first to dimension -a-.

1. Dimension -a- = maximum 100 mm (3.93 inches).

Slightly tension the threaded spindles on the 10 - 222 A.

Disconnect the connector -1- using the transmission range gear recognition switch -F208- using the T40138 and free up the wire.

Remove the push rod bolt -2-.

Remove the connecting rod bolt -3-.

Press the transmission off the engine and lower it carefully using the V.A.G 1383 A.

If the transmission removed is being replaced, then the following components must be changed

1. Removing the clutch module if necessary, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-092009)
2. Tunnel crossmember with the transmission mount and transmission support. Refer to «TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Special tools and workshop equipment required

1. Assembly Aid T40169
2. Transportation Lock T40170
3. Gearbox Support T40173
4. Engine-/Gearbox Jack V.A.G 1383 A Spindles 10 - 222 A /11
5. Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
6. Ring Spanner Insert AF16 V.A.G 1332/14
7. Hose Clamps Up to 25 mm in Dia. 3094

Procedure

Note. Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times. Replace self-locking nuts and bolts and seals, gaskets and O-rings. Secure all hose connections with hose clamps of the same type as those equipped by the factory, To secure the charge air hoses on their connections, spray the clamps used previously with rust remover before installing. When installing, bring all cable ties back to same positions.

Transmission installation tightening specifications TRANSMISSION, INSTALLING

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

Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate if necessary. Refer to Removal and Installation .

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

1. See if it is possible to use the aluminum bolts -2 through 11- again and mark them if necessary «TRANSMISSION, INSTALLING»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Installing the clutch module if necessary. Refer to Removal and Installation

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

Insert the T40169 in the transmission housing and the clutch module from below as shown in the illustration.

1. The T40169 must engage in the semi-circular opening -1- and into the check hole -2-.

Note. There is only 1 inspection opening on the circumference. Rotate the clutch module as needed.

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

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

Raise the transmission straight up until the clutch slave cylinder -1- can be inserted.

Tighten the bolt -2-. Tightening specification -item 17- CLUTCH HYDRAULICS OVERVIEW .

Note. The next step is only necessary if a drive plate with alignment pins -2- is installed.

Also align the drive plate to the clutch module so the alignment pins -2- on the drive plate (if applicable) can engage in the larger holes -1- on the clutch module.

Connect the transmission to the engine and tighten -3.... 11- the bolts. Tightening specifications TRANSMISSION, INSTALLING .

Install the starter and tighten the bolts -1 and 4-. Tightening specification TRANSMISSION, INSTALLING .

Raise the transmission using the V.A.G 1383 A until dimension -a- is reached between the subframe and the body.

1. a- = minimum 100 mm (3.93 inches)

Attach the push rod -1- -item 27- 27 .

Attach the connecting rod -3-. Tightening specification -item 25- 25 .

Connect the connector -2- to the transmission range gear recognition switch -F208-.

Install the transmission shift lever -2- as follows

1. The gearshift lever -2- can be attached to the gearshift shaft -1- in only one position (gap in the splines -arrow-).

Attach the transmission shift lever -2-. Tightening specification -item 18- 18 .

Loosen the 10 - 222 A /11.

Lift the transmission and tighten the tunnel crossmember bolts -arrows-. Tightening specifications, refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Remove the V.A.G 1383 A and T40173.

Install the left and right drive axles on the transmission flange shafts. Refer to Removal and Installation .

Install the drive axle heat shield. (Scheme 174)

Install the driveshaft. Refer to Removal and Installation or Removal and Installation .

Block the driveshaft. To do this, place the T10172 and T10172/5 on the driveshaft bolts on the transmission or the rear final drive.

Tightening Sequence - Clutch Module to the Drive Plate

Remove the T40169 and T40170.

Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in direction of -arrow- into 6th gear.

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

Turn both front wheel together in one direction until the clutch module turns one complete turn (360°).

1. The check hole -arrow- must be visible in the transmission housing cut-out.

Tighten the clutch module to the drive plate as follows

1. Use new bolts.
2. Tightening specification -item 3- «CLUTCH MODULE OVERVIEW»(/audi/a5/i-2007-2011/remont/clutches-manual-hydraulic/#clutch-manual-transmission-0b2-awd-coupe-as-of-022012__clutch-module-overview) .
3. Tighten the bolts using the V.A.G 1332/14.

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

Turn the clutch module 180° in engine direction of rotation over both front gears.

Insert the second bolt and tighten it. Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Install the remaining bolts and tighten them (and the one bolt that was installed earlier). Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Install in reverse order of removal. Note the following

Tighten the universal joint on the steering gear. Refer to Description and Operation .

Install the driveshaft heat shield -A- and tighten the bolts -arrows- to 25 Nm, if equipped.

Install the right catalytic converter. Refer to Removal and Installation .

Install the left and right front muffler. Refer to Removal and Installation .

Install the exhaust system so that it is free of tension. Refer to Removal and Installation .

Install the subframe crossbrace. Refer to Removal and Installation .

Gear oil level in manual transmission, checking. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

Install the noise insulation. Refer to Description and Operation .

Install the bulkhead plenum chamber. Refer to Removal and Installation .

Observe measures after connecting the battery. Refer to Removal and Installation .

TIGHTENING SPECIFICATIONS

Note. The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant. Do not use any ungreased parts. Tightening specification tolerance +/- 15%.

Tighten the heat shield bolts -arrows- to 23 Nm.

SECURING THE ENGINE TO THE MANUAL TRANSMISSION

1. Audi A4 from VIN 8K-9-066500 and Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.
2. Bolts marked with an "X" may not be used again.
3. Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.
4. Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.

TRANSMISSION, TRANSPORTING

Special tools and workshop equipment required

1. Transmission Lift Hook T40013
2. Shop Crane -Load Cap=700-1200kg VAS 6100

Procedure

Attach the T40013 to the transmission lifting eye and secure it.

Scheme 173

Engage the VAS 6100 hooks in 3rd mount -arrow- of the T40013

Lift transmission with VAS 6100 and T40013.

TUNNEL CROSSMEMBER

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Gearbox Support T10337

Scheme 174

Remove the rear noise insulation by loosening the fasteners -2 and 3

Position the V.A.G 1383 A plunger with the T10337 attached on the bottom of the transmission.

Lift the transmission slightly using the V.A.G 1383 A.

Remove the bolts from the tunnel crossmember -arrows-.

Remove the nuts -arrow- and the tunnel crossmember.

Scheme 175

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Install the noise insulation. Refer to Description and Operation .

Scheme 176

Remove the tunnel crossmember. Refer to TUNNEL CROSSMEMBER .

Remove the bolts -arrows- and the transmission support with the transmission mount from the transmission.

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Tighten the transmission support with the transmission mount on the transmission -arrows-.

Install tunnel crossmember. Refer to TUNNEL CROSSMEMBER .

Scheme 177

Remove the transmission support with the transmission mount. Refer to TRANSMISSION SUPPORT WITH TRANSMISSION MOUNT .

Remove the bolts -1- and remove the lower stop -2- for the transmission mount.

Remove the nut -4- and remove the transmission mount -5- from the transmission support -3-.

1. Tightening specifications, refer to «TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-manual-transmission-0b2-coupe) .

Mount the transmission support -3- on the transmission mount -5- and tighten the nut -4- hand-tight.

Tighten the lower stop -2- with the bolts -1-.

Tighten the nut -4-.

Install the transmission support and transmission mount. Refer to TRANSMISSION SUPPORT WITH TRANSMISSION MOUNT .

TRANSMISSION RANGE GEAR RECOGNITION SWITCH -F208

1. Transmission installed.

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Gearbox Support T10337
3. Release Tool f/ Rev. Light Switch Conn. T40138
4. Torque Wrench 5-50 Nm V.A.G 1331

Remove the rear noise insulation by loosening the fasteners -2 and -.

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.

Disconnect exhaust system at double clamp -arrow-.

Move the front exhaust pipe to the side and secure it on the rear section of the exhaust system (clamping sleeve) with wire.

Position the V.A.G 1383 A plunger with the T10337 attached on the bottom of the transmission.

Lift the transmission slightly using the V.A.G 1383 A.

Remove the bolts from the tunnel crossmember -arrows-.

Lower the transmission to dimension -a- using the V.A.G 1383 A.

1. Dimension -a- = maximum 80 mm (3.14 inches).

Disconnect the connector -arrow- using the T40138.

Scheme 178

Remove the transmission range gear recognition switch -F208- from the selector shaft cover.

Install in reverse order of removal. Note the following

Install the transmission range gear recognition switch -- in the selector shaft cover. Tightening specification Transmission Range Gear Recognition Switch -F208 .

Scheme 179

Install the connector -2- on the transmission range gear recognition switch --.

Note. Disregard -1 and 3-.

Install the tunnel crossmember -arrows- -2- 2 .

Re-assemble the exhaust system and ensure it is not under stress. Refer to REMOVAL AND INSTALLATION .

Install the noise insulation. Refer to Description and Operation .

Tightening Specification

GEAR RECOGNITION SENSOR

1. Transmission installed.

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Gearbox Support T10337
3. Torque Wrench 5-50 Nm V.A.G 1331

Remove the rear noise insulation by loosening the fasteners -2 and 3-.

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.

Disconnect exhaust system at double clamp -arrow-.

Move the front exhaust pipe to the side and secure it on the rear section of the exhaust system (clamping sleeve) with wire.

Position the V.A.G 1383 A plunger with the T10337 attached on the bottom of the transmission.

Lift the transmission slightly using the V.A.G 1383 A.

Remove the bolts from the tunnel crossmember -arrows-.

Lower the transmission to dimension -a- using the V.A.G 1383 A.

1. Dimension -a- = maximum 80 mm (3.14 inches).

Disconnect the connector -2-.

Note. Disregard -1 and 2-.

Remove the bolt -1- and remove the gear recognition sensor -G604- -3-.

Scheme 180

Install in reverse order of removal. Note the following

Replace the O-rings -4-.

Secure the gear recognition sensor -- with the bolt -1-. Tightening specification GEAR RECOGNITION SENSOR

Connect the connector -2-.

Install the tunnel crossmember -arrows-, tightening specifications -2- 2 .

Re-assemble the exhaust system and ensure it is not under stress. Refer to [For engine(s) CALA] Removal and Installation .

Install the noise insulation Description and Operation .

Tightening Specification

TRANSMISSION NEUTRAL POSITION SENSOR -G701

1. On for vehicles with the Start/Stop System.
2. Transmission installed.

Loosen the fasteners -2 and 3- and remove the rear noise insulation.

Move gearshift lever -2- forward in direction of -arrow- and shift into 4th gear.

Note. Ignore -1-.

Disconnect the connector from the transmission neutral position sensor -G701- -1-.

Remove the bolt -arrow- and remove the transmission neutral position sensor -- -A-.

Scheme 181

Note. The cover -B- remains installed.

Install the transmission neutral position sensor -- -A- with a new O-ring in the gearshift shaft cover -B-.

Tighten the new bolt -arrow- to the tightening specification Transmission Neutral Position Sensor -G701 .

Connect the connector to the transmission neutral position sensor -- -1-.

Install the noise insulation. Refer to Description and Operation .

Tightening Specification

SELECTOR SHAFT SEAL

1. Transmission installed.

Special tools and workshop equipment required

1. Pulling Hook T20143/1
2. Shock Absorber Set T10001/1
3. Puller for Gear Shaft Linkage T40160
4. Sealing Grease G 052 128 A1

Select 1st gear.

Remove the rear noise insulation by loosening the fasteners -2- and -3

Remove the nut -1-.

Note. Ignore -2-.

Mount the T40160 and remove the gearshift lever.

Pry out the shaft seal using the T20143/1.

Scheme 182

1. Check the selector shaft for damage.

Scheme 183

Lightly coat the outer circumference of the seal with oil.

Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

Install the shaft seal with T10001/1.

1. Installed dimension: 2 mm below the outer edge of the housing

Install the selector lever as follows

1. The gearshift lever -2- can be attached to the gearshift shaft -1- in only one position (gap in the splines -arrow-).

Tighten the selector lever. Tightening specification -item 18- 18 .

Install the noise insulation. Refer to Description and Operation .

TRANSMISSION, DISASSEMBLING AND ASSEMBLING

The appropriate description can be found on the repair information "6-Speed Manual Transmission 0B2 AWD, Servicing" : Refer to Disassembly and Assembly .

Scheme 184

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Ring Spanner Insert AF16 V.A.G 1332/14
3. Engine-/Gearbox Jack V.A.G 1383 A
4. Step Ladder VAS 5085
5. Puller for Gear Shaft Linkage T40160
6. Gearbox Support T40173

Special tools and workshop equipment required

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Shock Absorber Set T10001/1
3. Pulling Hook T20143/1
4. Hose Clamps Up to 25 mm in Dia. 3094
5. Trim Removal Wedge 3409
6. Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
7. Gearbox Support T10337
8. Transmission Lift Hook T40013
9. Puller for Gear Shaft Linkage T40160
10. Assembly Aid T40169
11. Transportation Lock T40170
12. Release Tool f/ Rev. Light Switch Conn. T40138
13. Hose Clamp Pliers V.A.G 1275
14. Engine-/Gearbox Jack V.A.G 1383 A
15. Hose Clip Pliers V.A.G 1921
16. Shop Crane -Load Cap=700-1200kg VAS 6100
17. Torque Wrench 5-50 Nm V.A.G 1331
18. Not illustrated
19. Engine Support Adapter 10 - 222 A /3
20. Spindle 10 - 222 A /11
21. Engine Support Basic Set T40091
22. Engine Support Supplement Set T40093
23. Connector T40091/3
24. Gearbox Support T40173

See also:
• Description and Operation
• CODE LETTERS, TRANSMISSION ALLOCATION, RATIOS AND CAPACITIES
• Removal and Installation
• [For engine(s) CAUA, CAEB, CALA] Removal and Installation
• [For engine(s) CAUA, CAEB, CALA] Removal and Installation
• Removal and Installation
• Removal and Installation
• [For engine(s) CALA] Removal and Installation
• Removal and Installation
• Removal and Installation
• Description and Operation
• Removal and Installation
• CLUTCH HYDRAULICS OVERVIEW
• CLUTCH MODULE OVERVIEW
• Removal and Installation
• Removal and Installation
• Disassembly and Assembly
• SHIFT KNOB WITH SHIFT LEVER BOOT
• NOISE INSULATION
• SELECTOR MECHANISM
• SELECTOR MECHANISM, ADJUSTING
• TUNNEL CROSSMEMBER
• TRANSMISSION, INSTALLING
• TRANSMISSION FLUID LEVEL, CHECKING
• Transmission Range Gear Recognition Switch -F208
• GEAR RECOGNITION SENSOR
• Transmission Neutral Position Sensor -G701