Transmission, Installing, 2.0L TDI Engine: Procedure

WARNING: This page is about a different car, the 2014 Audi A5, 2013 Audi A5, 2012 Audi A5, and 2011 Audi A5. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace any 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. Refer to the parts information.

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

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

-- 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 .

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

-- 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

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-- Attach the exhaust system retaining strap bracket -1- to the new transmission. Refer to OVERVIEW - MUFFLER [CAED, CAEB, CPMB, CPMA] .

-- 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 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 dual mass 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 4: Identifying Transportation Lock T40170

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NOTE:

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

Fig 5: Identifying Bolt & Spacer Sleeve

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

-- 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: Engine To Transmission Bolts (1 through 10)

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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.

-- Place the transmission on the engine and tighten the bolts -6 through 10- that connect the engine to the transmission.

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

VEHICLES WITH 4-CYLINDER TDI ENGINE (PR-TD1):

Fig 7: Identifying Torque Support And Bolts

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-- Loosen the bolt -1- for the torque support -2-, and remove the Brake Piston Retraction Tool:T40142 .

All Vehicles:

Fig 8: Identifying Bolts & Tunnel Crossmember

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

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

NOTE:

The following step is necessary to make sure the dual-mass flywheel rests on the drive plate evenly and is not tilted.

Fig 9: Pressing Flywheel Slightly Against Drive Plate

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

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

Fig 10: Identifying Offset Open-End Wrench

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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 bolt -arrow- and tighten to 60 Nm.

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

Install In Reverse Order Of Removal. Note The Following:

-- 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 driveshafts on the transmission flange shafts. Refer to OVERVIEW - DRIVE AXLE [CABRIOLET] (1 Of 2) / DRIVE AXLE THREADED CONNECTION, LOOSENING AND TIGHTENING / DRIVE AXLE [CABRIOLET] (2 Of 2) / DRIVE AXLE OVERVIEW [CABRIOLET] (2 Of 2) .

-- Install the driveshaft heat shield Figure.

-- Tighten the remaining engine/transmission connecting bolts -2 through 5-.

Fig 12: Engine To Transmission Bolts (1 through 10)

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NOTE:

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

Fig 13: Identifying Bolt & Spacer Sleeve

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

-- Install The Power Steering Hydraulic Lines. Refer to OVERVIEW - HYDRAULIC PIPES AND RESERVOIR .

-- Install The Subframe Crossbrace. Refer to SUBFRAME CROSSBRACE, COUPE AND SPORTBACK / SUBFRAME CROSSBRACE, CABRIOLET .

-- Install the diagonal braces. Refer to SUBFRAME CROSSBRACE, COUPE AND SPORTBACK / SUBFRAME CROSSBRACE, CABRIOLET .

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

-- Install the noise insulations. Refer to NOISE INSULATION, REMOVING AND INSTALLING / OVERVIEW - NOISE INSULATION .

-- Follow all steps after connecting 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 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 .

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