Transmission, Installing: Notes

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Special tools and workshop equipment required

Ring Spanner Insert AF16 V.A.G 1332/14
Transportation Lock T40170

Procedure

NOTE:

Replace bolts that are tightened to the specification.

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 same positions.

Transmission Installation Tightening Specifications: TRANSMISSION, INSTALLING .

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar). 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 TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

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

Fig 1: 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:

-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as illustrated.

Fig 2: Locating Hole Next To Notch

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NOTE:

There is only 1 notch on the circumference; rotate the torque converter as needed.

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

Fig 3: 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 4: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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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 TRANSMISSION, INSTALLING .

-- Attach the transmission to the engine and the tighten the bolts -1 and 6 through 11-.

-- Remove the T40170.

-- Clip the locking piece -1- into the starter opening.

Fig 5: Identifying Locking Piece

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The locking piece -1- must be installed so that it fits correctly -arrows-.

NOTE:

There are different versions of the locking piece depending on the engine.

Apply some grease to the locking piece if it is difficult to install the starter.

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

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

Fig 6: Identifying Tunnel Crossmember

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-- Loosen the tension strap and remove the V.A.G 1383 A with the T40173 from under the transmission.

NOTE:

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

-- Press the torque converter -2- against the drive plate -3- slightly in the direction of the -arrow- using an assembly lever -1-.

Fig 7: Pressing Torque Converter

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-- Attach the torque converter to the drive plate as follows:

Fig 8: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Use the ring spanner insert AF16 V.A.G 1332/14 to tighten.

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

-- Turn the crankshaft 180° in direction of engine rotation -arrow- using the T10172 with T10172/7

Fig 9: Counterholding Crankshaft With T10172 With T10172/7 To Loosen Flywheel Bolts

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-- With the crankshaft in this position, tighten the bolt -arrow- to 60 Nm.

Fig 10: Identifying Clutch Module First Bolt Installation Location

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-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification.

-- Tighten the remaining bolts -2 through 5-.

Fig 11: Tightening Remaining Bolts -2 Through 5-

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Install in reverse order of removal paying attention to the following:

-- Attach the steering column to the steering gear. Refer to STEERING COLUMN .

Fig 12: Locating Universal Joint Bolt

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-- Install the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

Fig 13: Locating Power Steering Hydraulic Line

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-- Install selector lever cable. Refer to SELECTOR LEVER CABLE .

-- Install the ATF pipes. Refer to AUTOMATIC TRANSMISSION COOLER AND LINES OVERVIEW .

-- Attach the left and right drive axles to the transmission flange shafts. Refer to FRONT SUSPENSION .

-- Install the driveshaft heat shield TRANSMISSION, INSTALLING .

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

-- Reconnect exhaust system making sure it is not under stress. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

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

-- Install the bulkhead plenum chamber. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Connect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Check the selector lever cable and adjust if necessary. Refer to SELECTOR LEVER CABLE, ADJUSTING .

-- Check the ATF level and correct if necessary. Refer to ATF, CHECKING LEVEL AND CORRECTING .