Transmission, Installing

Special tools and workshop equipment required 

• Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
• Clutch Module Assembly Aid T40169
• Clutch Module Transportation Lock T40170

Procedure 

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar (145 psi)). Refer to AUTOMATIC TRANSMISSION FLUID LINES, CLEANING .

-- Clean residue from the threaded holes in the cylinder block using a thread tap before installing.

-- When installing a replacement transmission, install the transmission support, the transmission mounting and the tunnel crossmember on the new transmission. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 1: Attach Exhaust System Retaining Strap Bracket To New Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Attach the exhaust system retaining strap bracket -1- to the new transmission. For engine code CALA, refer to OVERVIEW - MUFFLER , see figure 5. For engine code CCBA, CGXC, CTUB, refer to OVERVIEW - MUFFLER , see figure 4 and for engine codes CAED, CAEB, CPMB, CPMA, refer to OVERVIEW - EMISSIONS CONTROL , see figure 30. .

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

Fig 2: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

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

Fig 3: Insert Assembly Aid T40169 Into Transmission Housing

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

The tool must grip into the semicircular hole and also in the hole -arrow A- and -arrow B-.

Fig 4: Inserting Clutch Module Assembly Aid T40169 Into Transmission And Dual Mass Flywheel

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-- 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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-- 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 -A- For Centering Engine/Transmission Are In Cylinder Block And Insert Them If They Are Not

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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 MOUNT TO TFSI ENGINE , refer to footnotes in table "Audi A4 from VIN 8K-9A-066500, Audi A5 from VIN 8T-9A-008000: The aluminum bolts -2 through 11- may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-".

-- Place the transmission on the engine and tighten the bolts -2 through 6- that connect the engine to the transmission.

NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Fig 7: Identifying Bolt & Spacer Sleeve

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The spacer sleeve must be inserted between the starter and the transmission.

-- Loosen the Engine Support Bridge - Spindle 10-222A/11

Fig 8: Installing 10 - 222 A With 10 - 222 A /3 On Left And Right Strut Towers

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-- Lift the transmission and install the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, REMOVING AND INSTALLING .

Fig 9: Identifying Bolts & Tunnel Crossmember

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-- Loosen the tensioning strap and guide the Engine and Gearbox Jack VAS6931 with the Gearbox Support T40173 under the transmission.

-- Turn the crankshaft on the vibration damper 360° in the direction of engine rotation.

Fig 10: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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

NOTE:

Use the Torque Wrench 1331 Insert - Open Jaw - 13mm VAG1332/14 to tighten the bolts.

Fig 11: 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-, tighten to 10 Nm, loosen and then tighten to 2 Nm (hand-tight).

-- Turn the crankshaft on the vibration damper 120° in the direction of engine rotation.

-- With the crankshaft in this position, install the next bolt and tighten to 60 Nm.

-- Turn the crankshaft in another 120° the direction of engine rotation and install the next bolt and tighten to 60 Nm.

-- Turn the crankshaft another 120° the direction of engine rotation and tighten the last bolt to 60 Nm.

Install in reverse order of removal. Note the following:

Fig 12: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block And Insert Them If They Are Not

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-- Tighten the remaining engine/transmission connecting bolts -1, 7 through 11-.

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

-- Install selector lever cable. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Install the ATF pipes. Refer to OVERVIEW - ATF CIRCUIT .

-- Tighten the left and right drive axles on the transmission flange shafts. Refer to DRIVE AXLE .

-- Install the driveshaft heat shield. Refer to Figure.

-- Install the subframe crossbrace. Refer to OVERVIEW - SUBFRAME .

-- Install the diagonal braces. Refer to OVERVIEW - SUBFRAME .

-- Install the noise insulations. Refer to NOISE INSULATION .

-- Follow all steps after connecting the battery. Refer to CONNECTING .

-- 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 .

-- After repairing the transmission, check the axle oil level in the front final drive and adjust if necessary. Refer to GEAR OIL, CHECKING LEVEL .