Transmission, Installing: Notes
Special tools and workshop equipment required
- Ring Spanner Insert AF 16 V.A.G 1332/14
- Assembly Aid T40169
- Transportation Lock T40170
Transmission installation tightening specifications: TIGHTENING SPECIFICATIONS
Procedure
Replace bolts that are tightened to the specification.
Replace self-locking nuts and bolts and seals, gaskets and O-rings.
The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
Secure all hose connections with hose clamps of the same type as those equipped by the factory.
To secure the air guide hoses on their connections, spray the clamps used previously with rust remover before installing.
When installing, bring all cable ties back to same positions.
There are 2 different ATF filter versions depending on the engine and the date of manufacture. ATF pipe filter -5- and ATF filter -10-.
- ATF filter -10-, must be replaced at every ATF change or whenever a repair is made to the transmission.
- ATF pipe filter -5-, must be replaced whenever the transmission is replaced or if the ATF is very dirty. for removing and installing, refer to ATF PIPE FILTER .
Danger of damaging the components.
If a transmission with an ATF pipe filter -5- is replaced by a transmission with an ATF filter -10-.
- If the supply and return ATF pipe must be replaced, refer to ATF PIPES . The ATF pipes are NOT the same. The ATF lines will leak or get damaged if they are not replaced.
- The ATF filter -10- must be changed at every ATF change in the future. Enter these in the vehicle data and in the repair history. The ATF filter change is not always automatically displayed in the Maintenance schedule.
-- Clean the ATF pipe and the ATF cooler after replacing the transmission or after repairing the transmission. Refer to ATF PIPES AND ATF COOLER, CLEANING .
-- Always clean the threaded holes for the engine/transmission bolts in the cylinder block before assembling the transmission using a thread cutter.
Danger of leaks in the ATF pan.
- Do not set the T40173 on the ATF pan.
-- Mount the V.A.G 1383 A with the prepared T40173 to the bottom of the transmission.
The transmission support must be placed at the front as follows:
- The bracket -2- fits into the flywheel on the transmission housing on the left side of the transmission.
- The transmission support is installed with an elastic washer -1- on the center differential housing on the right side of the transmission.
-- Secure the transmission with a tensioning strap -1-.
-- 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 illustrated.
- The assembly tool must engage in the semi-circular opening -1- and into the check hole -2-.
There is only 1 inspection opening on the circumference. Rotate the flywheel as needed.
-- Install the bolts from the assembly device into the holes on the transmission housing.
-- Insert the T40170 into the transmission housing from underneath and clamp it secure to the flange shaft -1-.
-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary TRANSMISSION, INSTALLING .
-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.
-- Connect the transmission to the engine and then tighten the engine/transmission connecting bolts -6 and 7-.
-- Install the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .
The V.A.G 1383 A is not shown in the illustration.
-- Lower the V.A.G 1383 A with the T40173 and move it to the side.
-- Tighten then engine bolts to the transmission accessible from underneath.
-- Remove the T40170 and T40169.
The following step is necessary to make sure the flywheel rests on the drive plate evenly and is not tilted.
-- Push the flywheel slightly against the drive plate -3- -arrow- -2- using a pry bar -1-.
Vehicles with 6-Cylinder Engine
Tighten the bolts with the V.A.G 1332/14.
-- Tighten the flywheel to the drive plate as follows:
-- Install the first bolt -arrow- and tighten by hand (2 Nm).
-- Insert the T40058 guide pins as follows:
- The large diameter -arrow 1- faces the engine.
- The small diameter -arrow 2- faces the adapter.
-- Continue turning the crankshaft on the vibration damper 180° in the direction of the engine rotation -arrow- using the T40058.
-- Tighten the bolt with the crankshaft in this position. Refer to CLUTCH .
-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification. Refer to CLUTCH .
Vehicles with 8-Cylinder Engine
Tighten the bolts with the V.A.G 1332/14.
-- Tighten the flywheel to the drive plate as follows:
-- Install the first bolt -arrow- and tighten by hand (2 Nm).
-- Turn the crankshaft on the vibration damper 180° in direction of engine rotation -arrow- using T10172 with T10172/7.
-- Tighten the bolt with the crankshaft in this position. refer to CLUTCH .
-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification. Refer to CLUTCH .
All Vehicles
Install in reverse order of removal. Note the following:
-- Attach the steering intermediate shaft to the steering gear. Refer to STEERING GEAR .
-- Install selector lever cable. Refer to SELECTOR LEVER CABLE .
-- Install the ATF pipes. Refer to 6-cylinder engine ATF PIPES or 8-cylinder engine ATF PIPES .
-- Attach the left and right drive axles to the transmission flange shafts. Refer to FRONT AXLE .
-- Install the drives axle heat shield. Refer to Figure.
Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive repair information.
-- Install the driveshaft. Refer to REMOVAL AND INSTALLATION .
-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .
-- Tighten the remaining engine/transmission connecting bolts -3 through 5-.
-- Install the exhaust system and align it free of tension. Refer to EXHAUST PIPES/MUFFLERS .
-- Install the plenum chamber bulkhead. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
Vehicles with Hydraulic Power Steering
-- Install the power steering hydraulic lines. Refer to POWER STEERING HYDRAULICS .
All Vehicles
-- Install the subframe crossbrace. Refer to SUBFRAME .
-- Install the diagonal braces. Refer to SUBFRAME .
-- Install the drive axle covers and noise insulation. Refer to NOISE INSULATION .
-- Complete the steps required after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
Danger of causing damage to the control modules due to the excess voltage.
- Do not use a charger to jump start!
-- Check the selector lever cable and adjust if necessary. Refer to SELECTOR LEVER CABLE, ADJUSTING .
Vehicles with Hydraulic Power Steering
-- Fill the power steering fluid. Refer to POWER STEERING HYDRAULICS .
All Vehicles