Transmission, Installing: Procedure

NOTE:

Replace the bolts that were tightened with an additional turn.

Replace self-locking nuts and bolts and seals, gaskets and o-rings.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

To secure the air guide hoses on their connections, spray the clamps used previously with rust remover before installing.

When installing, bring all cable ties back to same positions.

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

Fig 1: Identifying Elbow Of Bleeder Hose

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

-- Press on the loose elbow until it audibly engages.

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

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

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

Fig 2: Identifying Elbow Of Bleeder Pipe

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

-- Press on the loose elbow until it audibly engages.

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

All vehicles:

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

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

Fig 3: Securing Transmission With A Tensioning Strap

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CAUTION:

Danger of leaks in the ATF pan.

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

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

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

Fig 4: Insert Assembly Aid T40169 Into Transmission Housing

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

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

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

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

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

Fig 5: Identifying Transportation Lock T40170

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-- 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, refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

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

Fig 6: Checking If Alignment Sleeves For Centering Engine/Transmission Are In Cylinder Block

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

-- Install the tunnel crossmember, refer to OVERVIEW - SUBFRAME MOUNT .

NOTE: The illustration id shown without the Engine and Gearbox Jack VAS 6931.

-- Lower the Engine and Gearbox Jack VAS 6931 with the Gearbox Support T40173 and set aside.

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

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

NOTE:

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

Fig 7: Pressing Torque Converter

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

NOTE:

Use the Torque Wrench 1331 Insert - Open Jaw - 13 mm VAG 1332/14 to tighten the bolts.

Fig 8: Identifying Clutch Module First Bolt Installation Location

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-- Tighten the flywheel to the drive plate as follows:

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

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

Fig 9: Identifying Guide Pin And Adapter T40058

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-- Insert the adapter T40058 guide pins as follows:

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

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

Fig 10: Counter Hold Crankshaft Using Socket T40058

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

-- Tighten the bolt with the crankshaft in this position, refer to OVERVIEW - FLYWHEEL AND DUAL CLUTCH .

-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification, refer to OVERVIEW - FLYWHEEL AND DUAL CLUTCH .

Vehicles with a 8-cylinder gasoline engine:

Fig 11: Identifying Crankshaft Turning Tool T40272

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

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

NOTE: Ignore the notch on the Crankshaft Turning Tool T40272.

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

-- Tighten the bolt with the crankshaft in this position, refer to OVERVIEW - FLYWHEEL AND DUAL CLUTCH .

-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification, refer to OVERVIEW - FLYWHEEL AND DUAL CLUTCH .

All vehicles:

Install in reverse order of removal. Note the following:

-- Install selector lever cable, refer to Installing .

-- Install the starter, refer to STARTER (CEUC, CRDB) .

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

Fig 12: Checking If Alignment Sleeves For Centering Engine/Transmission Are In Cylinder Block

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-- Install the Transmission Fluid Cooling Valve -N509-, refer to Transmission Fluid Cooling Valve -N509-, REMOVING AND INSTALLING .

-- Install the coolant pipe, refer to COOLANT PIPES, REMOVING AND INSTALLING .

-- Installing the ATF cooler, refer to OVERVIEW - ATF CIRCUIT .

-- Attach the steering intermediate shaft to the steering gear, refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information .

-- Install the driveshaft, refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING .

-- Installing the drive axle and drive axle heat shield, refer to Drive Axle .

-- Install the subframe heat shield, refer to HEAT SHIELDS AND CROSSBRACES .

-- Install the subframe crossbrace, refer to Subframe Crossbrace, Removing And Installing .

-- Install the fan shroud, refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Fill the engine coolant, refer to Draining .

-- Install the plenum chamber bulkhead, refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the exhaust system, refer to OVERVIEW - MUFFLER .

-- Install the drive axle covers and noise insulation, refer to OVERVIEW - FRONT AND REAR NOISE INSULATION .

-- Install the front wheels, refer to 44 WHEELS, TIRES, WHEEL ALIGNMENT .

-- Observe measures after connecting the battery, refer to Battery -A-, Disconnecting And Connecting .

CAUTION:

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

Do not use a charger to jump start!

-- Check and adjust the selector lever cable, refer to SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Check the ATF level and correct if necessary, refer to ATF LEVEL, CHECKING .

-- Check transmission fluid level and fill, refer to TRANSMISSION FLUID LEVEL, CHECKING .