Transmission, Removing And Installing, Vehicles With V6 TDI Engine: Installing: Notes

Install In Reverse Order Of Removal While Noting The Following: 

Clean the ATF cooler and the ATF lines if the ATF is dirty or before installing a replacement transmission. Refer to ATF PIPES AND ATF COOLER, CLEANING .

Use a wire brush to clean the threads of the bolts that were installed with locking fluid. Then insert the bolts with Locking Fluid:AMV 185 101 A1  .

Use a thread cutter to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.

-- Always replace self-locking bolts and nuts.

-- Reconnect all electrical connections, lines, hoses, and connectors that were disconnected during removal.

-- Make sure the torque converter is inserted correctly inside the transmission before installing the transmission. Refer to TORQUE CONVERTER, INSTALLING .

-- Check installation dimension -a-. Refer to Figure

Fig 1: Measuring Torque Converter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before installing the transmission to the engine, make sure there are alignment sleeves for centering the engine/transmission or install them if needed.

-- If a replacement transmission is installed, it must be positioned on the :VAG1359/2  as done during removal. Secure the transmission with a :T10038  .

-- Align the transmission to the engine and install.

-- When attaching the transmission to the engine, always make sure the converter is >>rotating freely<< and not jammed.

-- Tighten Engine/Transmission Connecting Bolts -3 Through 10- To The Tightening Specification.

Fig 2: Bolt Removal Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the six new torque converter bolts -arrows- in the drive plate -2- (turn the crankshaft another ¹ /₃ turn in direction of engine rotation).

Fig 3: 6 Torque Converter Bolts -Arrows- & Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Tightening Specification: 85 Nm. 

-- Install cap -1-.

-- Install the starter. Refer to STARTER, VEHICLES WITH AUTOMATIC TRANSMISSION .

-- Bolt the ATF preheater -arrows- to the transmission, install the coolant pipes on the transmission and connect with the coolant hoses.

Fig 4: Identifying Pre-Heater Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the plug and insert the ATF lines all the way into the transmission.

Fig 5: Identifying Transmission Fluid Pipe Bolts -1 And 2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the bolts -1 and 2-. Refer to ATF PIPES, REMOVING AND INSTALLING .

-- Carefully install the selector lever cable ball head -1- on the lever/selector shaft. Do not bend the lever/selector shaft when doing this or else shifting can no longer be adjusted precisely.

Fig 6: Identifying Selector Lever Cable, Removal/Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Replace clip -3-.

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

-- Install the heat shields and the catalytic converter bracket on the transmission.

-- Install the catalytic converter. Refer to CATALYTIC CONVERTERS, REMOVING AND INSTALLING [CGRA] , EMISSIONS CONTROL [CGFA] and EXHAUST SYSTEM COMPONENTS [CATA] .

-- Attach the steering column universal joint to the steering gear. Refer to STEERING COLUMN, REMOVING AND INSTALLING .

-- Install the transfer case and transmission support. Refer to TRANSFER CASE, REMOVING AND INSTALLING .

-- Install The Diesel Particulate Filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING [CATA .

-- Install the front and rear driveshafts. Refer to DRIVESHAFT .

-- Install The Rear Section Of The Exhaust System. Refer to MUFFLER AND CATALYTIC CONVERTERS [CGRA] , EMISSIONS CONTROL [CGFA] and EXHAUST SYSTEM COMPONENTS [CATA] .

Check the ATF level and fill if necessary. Refer to ATF LEVEL, CHECKING AND FILLING .

-- Add coolant. Refer to COOLANT, FILLING [CGRA] , COOLANT, DRAINING AND FILLING [CGFA] and COOLANT, FILLING [CATA] .