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Elsa online. ElsaWin. ElsaWeb. AudiPower transmission7-speed dual clutch gearbox 0B5 (S tronic)Gearbox mechanics,operation, construction,diff.Removing and installing gearboxInstalling gearbox

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Installing gearbox
Special tools and workshop equipment required
    
t  Ring spanner insert, 16 mm -V.A.G 1332/14-
   W00-1329
t  Assembly aid -T40169-
   W00-10593
t  Transportation lock -T40170-
Tightening torques for installing gearbox: → Anchor
Procedure
  Note
t  Renew bolts which are tightened by turning through a specified angle.
t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets.
t  Hose connections and air pipes and hoses must be free from oil and grease before fitting.
t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue.
t  To ensure that the air hoses can be connected securely, you must spray the screw threads on used screw-type clips with rust remover prior to installation.
t  Re-attach all cable ties at the same locations when re-installing.
   W00-10594
Checking proper installation of breather hose - vehicles with 6-cylinder engine:
l  Angled connector of breather hose -2- must be pressed onto connection -1-.
–  If loose, press angled connector on until it engages audibly.
–  Check that mounting clip -3- is seated properly:
l  The distance between mounting clip (rear) and housing flange must measure 130 mm.
   A34-10924
Checking proper installation of breather pipe - vehicles with 8-cylinder engine:
l  Angled connector of breather pipe -2- must be pressed onto connection -1-.
–  If loose, press angled connector on until it engages audibly.
l  Retaining pin of breather pipe must be fitted into bolt head -5-.
l  Bolt -4- must be tightened to 10 Nm.
  Note
ATF breather -3- must remain clear.
Continued for all vehicles:
–  Clean ATF lines and ATF cooler after renewing or repairing gearbox → Chapter.
–  Before installing gearbox, it is important to clean any residue from threads for engine/gearbox connection in cylinder block using a tap.
   A34-10925
  Caution
Risk of leaks on ATF oil pan.
Do not apply gearbox support -T40173- at ATF oil pan.
–  Position gearbox on gearbox support -T40173- and secure with tensioning strap -1-, as shown in illustration.
   A34-10660
–  The following preparations must be made before joining the engine and gearbox:
–  Insert assembly aid -T40169- into gearbox housing and flywheel from below, as shown in illustration.
l  The assembly tool 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 flywheel accordingly.
–  Insert pin of assembly aid into hole on gearbox housing.
   A10-10825
–  Insert transportation lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-.
–  Check whether aluminium bolts for engine/gearbox connection can be reused and mark bolts if necessary → Anchor.
   A10-10826
–  Check that dowel sleeves -A- for centralising engine/gearbox are in the cylinder block; install any missing dowel sleeves.
–  Join gearbox with engine and tighten bolts -6- and -7-.
–  Secure tunnel cross member → Chapter.
  Note
The illustration does not show engine and gearbox jack -V.A.G 1383 A-.
–  Lower engine and gearbox jack -V.A.G 1383 A- with gearbox support -T40173- and move aside.
–  Tighten engine/gearbox connecting bolts accessible from below.
–  Remove transportation lock -T40170- and assembly aid -T40169-.
  Note
   A34-10471
The following step is necessary to ensure that the clutch module makes even and proper contact on the drive plate and does not cant.
–  Slightly press flywheel -2- using lever -1- against drive plate -3- in direction of -arrow-.
  Note
   A34-10497
Use ring spanner insert, 16 mm -V.A.G 1332/14-, to tighten bolts.
–  Secure flywheel to drive plate as follows:
–  Install first bolt -arrow- and tighten hand-tight (2 Nm).
   A10-10629
Vehicles with 6-cyl. petrol engine or 6-cyl. TDI engine:
–  Insert guide stud of adapter -T40058- as follows:
l  The larger diameter -arrow 1- faces engine.
l  The smaller diameter -arrow 2- faces adapter.
   A13-10026
–  Turn crankshaft at vibration damper 180° in direction of engine rotation -arrow- with adapter -T40058-.
  Note
Illustration shows 6-cylinder TFSI petrol engine. Other versions are similar.
–  Tighten bolt accessible in this crankshaft position to specified torque → Chapter.
–  Turn crankshaft 60° further each time and tighten remaining 5 bolts to specified torque → Chapter.
   A13-10651
Vehicles with 8-cyl. petrol engine:
–  Apply turning over tool -T40272- to bolts on vibration damper.
l  The semi-circular recess -arrow A- on turning over tool -T40272- faces semi-circular recess -arrow B- on vibration damper..
  Note
Disregard notch on turning over tool -T40272-.
–  Turn crankshaft at vibration damper 180° in direction of engine rotation -arrow- using turning over tool -T40272- and angled ring spanner.
–  Tighten bolt accessible in this crankshaft position to specified torque → Chapter.
–  Turn crankshaft 60° further each time and tighten remaining 5 bolts to specified torque → Chapter.
Continued for all vehicles:
The remaining installation steps are carried out in reverse sequence; note the following:
–  Install selector lever cable → Chapter.
–  Install starter →Electrical system; Rep. gr.27.
   A37-11101
–  Tighten remaining gearbox/engine securing bolts -3 … 5-.
–  Install coolant valve for gearbox -N488- →Engine, mechanics; Rep. gr.19.
–  Install coolant pipe (bottom left) →Engine, mechanics; Rep. gr.19.
–  Install ATF cooler → Chapter.
–  Secure intermediate steering shaft to steering box →Running gear, front-wheel and four-wheel drive; Rep. gr.48.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Install heat shield for drive shaft → Fig..
  Note
Please refer to the vehicle data sticker or the identification on the rear final drive to find out which type of rear final drive is installed in the vehicle. Then select the appropriate Workshop Manual for the rear final drive.
–  Install propshaft →Rear final drive 0BC; Rep. gr.39 or →Rear final drive 0BF and 0BE - sport differential; Rep. gr.39.
–  Secure drive shafts (left and right) to flange shafts on gearbox →Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.
–  Install heat shield on subframe →Rep. gr.40.
–  Install cross brace →Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.
–  Install coolant pipe on gearbox (right-side) →Engine, mechanics; Rep. gr.19.
–  Install radiator cowl →Engine, mechanics; Rep. gr.19.
–  Fill cooling system →Engine, mechanics; Rep. gr.19.
–  Install plenum chamber partition panel →General body repairs, exterior; Rep. gr.50.
–  Install exhaust system →Engine, mechanics; Rep. gr.26.
–  Install covers for drive shaft and noise insulation panels →General body repairs, exterior; Rep. gr.66.
–  Install front wheels →Wheels and tyres; Rep. gr.44.
–  Observe measures required after connecting battery →Electrical system; Rep. gr.27.
  Caution
Overvoltage can cause irreparable damage to control units.
Do not use charger for boost starting.
–  Check selector lever cable and adjust if necessary → Chapter.
–  Check ATF level and top up as required → Chapter.
–  Check gear oil level and top up as required → Chapter.
Tightening torques
  Note
t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.
t  Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.
t  Do not use parts which have been degreased.
t  Tolerance for tightening torques is ± 15 %.
   A34-10471
Component Nm
Bolts and nuts M6 9
M7 15
M8 20
M10 40
M12 65

   
Heat shield for drive shaft - tightening torque
–  Tighten bolts -arrows- for drive shaft heat shield to 23 Nm.
   A37-10841
Dual clutch gearbox to 6-cyl. or 8-cyl. petrol engine
   A34-10471
Item Bolt Nm
1 1) M10x50 2) 65
2 1), 3 … 6 M12x100 3) 30 + 90°
7 M12x125 3) 30 + 90°
8 M10x60 3) 15 + 90°
9, 10 M10x95 3) 15 + 90°
A Dowel sleeves for centralising
l  1) Also secures starter.
l  2) Property class 10.9; the steel bolt can be re-used any number of times.
l  3) Bolts can be used twice only → Anchor.

   
Dual clutch gearbox to 6-cyl. TDI engine
   A34-10471
Item Bolt Nm
1 1) M10x50 2) 65
2 1), 3 … 6 M12x100 3) 30 + 90°
7 M12x125 3) 30 + 90°
8 M10x60 3) 15 + 90°
9, 10 M10x95 3) 15 + 90°
A Dowel sleeves for centralising
l  1) Also secures starter.
l  2) Property class 10.9; the steel bolt can be re-used any number of times.
l  3) Bolts can be used twice only → Anchor.

   
t  Aluminium bolts -2 … 10- can be used twice only. After they have been used once, an „X“-arrow- must therefore be chiselled onto the bolts.
t  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.
t  Bolts marked with an „X“ must not be used again.
   A10-11113

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