Transmission, Installing: Notes

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Special tools and workshop equipment required

Ring Spanner Insert AF16 VAG 1332/14
Transportation Lock T40170

Procedure

NOTE:

Replace bolts that are tightened to the specification. Aluminum bolts used for attaching the transmission to the engine may be used one time only Figure.

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: Tightening specifications .

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

Fig 1: Securing Transmission With Tensioning Strap

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

-- Turn the torque converter so that the 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 transportation lock 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: Mounting Transmission To Engine

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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 Figure.

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

-- Remove the transport protection T40170.

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

Fig 5: Identifying Crossmember & Bolts

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-- Loosen the tension strap and remove the engine/transmission jack VAG 1383 A with the transmission support T40173 from under the transmission.

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

Fig 6: Identifying Locking Piece

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Make sure locking piece -1- is installed correctly before installing the starter -arrows-.

NOTE:

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

-- Install the starter. While doing this, install the spacer -arrow- on the bolt -2- between the starter and the transmission. Refer to STARTER .

Fig 7: Identifying Transmission Bolt & Spacer

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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 8: Pressing Torque Converter

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

Fig 9: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Use the ring spanner insert AF16 VAG 1332/14 to tighten.

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

-- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the counter hold tool T10355.

Fig 10: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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

Fig 11: Identifying Clutch Module First Bolt Installation Location

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-- Continue turning the crankshaft 120° and tighten the remaining 2 bolts to the tightening specification.

-- Tighten the remaining engine/transmission connecting bolts -3 through 5-.

Fig 12: Mounting Transmission To Engine

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NOTE:

The bolts -3- and -5- also attach the wire bracket on the transmission.

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

-- Install the ATF pipes. Refer to ATF PIPES .

-- Attach the selector lever cable to the transmission. Refer to SELECTOR LEVER CABLE .

-- Attach the steering column to the steering gear. Refer to OVERVIEW - STEERING COLUMN -item 18- "Bolt" .

Fig 13: Locating Steering Column Universal Joint Bolt

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-- Attach the left and right drive axles to the transmission flange shafts. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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

Fig 14: Locating Power Steering Hydraulic Line

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-- Install the drive axle right heat shield Driveshaft Heat Shield - Tightening Specification .

-- Install the right subframe shield under the right drive axle. Refer to SUBFRAME HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to REMOVAL AND INSTALLATION .

-- Install the exhaust system free of tension. Refer to EXHAUST PIPES/MUFFLERS for engine code CALA, EXHAUST PIPES/MUFFLERS for engine codes CAED, CAEB, CPMB, CPMA, or EXHAUST PIPES/MUFFLERS for engines CCBA, CGXC, CTUB.

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

-- Be sure to follow the procedure for connecting the battery afterwards. Refer to OVERVIEW - BATTERY .

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 .