Transmission, Installing, 2.7L/3.0L TDI Engine: Procedure

-- 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 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 [CAEB, CPMA, CAED, CPMB] .

-- 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 Clutch Module Assembly Aid:T40169  must engage in the semi-circular opening -1- and into the check hole -2-.

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

Fig 5: 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.

-- Place the transmission on the engine and tighten the bolts -7 through 11- that connect the engine to the transmission.

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

-- Install 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 flywheel rests on the drive plate evenly and is not tilted.

Fig 6: Pressing Flywheel Slightly Against Drive Plate

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-- Push the 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 7: Identifying Wrench - 21 MM T40263

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-- The check hole -arrow- must be visible in the transmission housing cut-out.

Fig 8: Locating Transmission Housing Check Hole

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NOTE:

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

Fig 9: 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 180° 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 60° 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 -3 through 5-.

Fig 10: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

-- Install the particulate filter and the front exhaust pipe. Refer to OVERVIEW - MUFFLER [CAEB, CPMA, CAED, CPMB] .

-- 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 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 .

-- 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 .