Sensor Module --, WITH INTEGRATED TRANSMITTERS AND SENSORS -G612-, -G632-, -G676 - AND Circuit Board 3 --, REMOVING AND INSTALLING: Installing

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Fig 1: Wrapping Tape Around Input Shaft Splines

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Tightening specifications. Refer to OVERVIEW - TRANSMISSION .

NOTE:

Replace any bolts that were tightened with an additional turn.

There are different versions of the sensor module -- and screw, depending on the date of manufacture.

-- Wrap the splines for the outer drive axle with adhesive tape in direction of -arrow-, so that the inner surfaces of the suction jet pump are not damaged when installing.

-- Coat the tape lightly with grease.

-- Remove the shaft seal for the separator in the transmission housing starting from the transmission side with a screwdriver in direction of -arrow-.

Fig 2: Removing Both Shaft Seals From Transmission Side Using Screwdriver

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NOTE:

Both of the shaft seals for the separator in the transmission housing must always be replaced.

To prevent damaging the seals there are pushed in after assembling the transmission housing with the intermediate housing.

-- Insert the Sensor Module -- into the guide openings and tighten it -arrow-.

Fig 3: Inserting Sensor Module Into Guide Holes

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-- Replace the oil catch tray.

-- Insert the front oil catch tray into the holes in the gear carrier and into the guide on the Sensor Module -- -arrows-.

Fig 4: Inserting Front Oil Catch Tray Into Gear Carrier Holes And Sensor Module Guide

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The oil catch tray must click into place.

Prepare the connector for the Sensor Module -- for installation:

Fig 5: Checking Connector Is Secured On Bracket

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NOTE:

It is necessary to replace the O-ring on the connector -2- for the Sensor Module -- if the Sensor Module -- is not being replaced.

-- Check whether the connector -2- is secured on the bracket -1- for the Sensor Module --.

-- Push the connector housing -3- onto the connector until it clicks into place. Do not turn it.

-- Coat the gear position seals with MTF, refer to OVERVIEW - TRANSMISSION -item 3- Gear Position Seal (See Figure).

-- Check if the retaining tabs in -4- can be pushed in.

-- Check the oil catch tray seating.

-- Check the seating of the sensor module seals -5-.

-- Adjust the transmission housing on the engine/transmission holder so that it is vertical.

Fig 6: Identifying Holding Plate And Hook and Support Tool

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-- Move the gearshift lever all the way in direction of travel in direction of -arrow-.

Fig 7: Moving Shift Lever In Direction Of Travel

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-- Make sure the alignment sleeves -1 and 2- are installed inside the transmission housing.

Fig 8: Making Sure Alignment Sleeves Are Installed

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NOTE:

The transmission housing sealing surface must be lightly roughened before the assembly.

Pay attention while doing so that no debris get into the transmission housing.

Suitable abrasive for example 3M bristle disk

-- Coat the transmission housing flange -arrow- evenly and lightly with sealant.

-- Make sure the magnet -arrow- is installed inside the transmission housing.

Fig 9: Placing Magnet Inside Transmission Housing

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-- Insert the front final drive oil guide into the transmission housing.

Fig 10: Inserting Front Final Drive Oil Guide Into Transmission Housing

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The oil guide must be inserted into the holes in the transmission housing at three locations -arrows-.

-- Install the Guide Pins - Gearbox T40288 in the threaded holes approximately 120° offset.

Fig 11: Installing Guide Pins - Gearbox T40288

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-- Engage the transmission intermediate housing -1- with the wheel set on the Shop Crane VAS6100 as shown in the illustration.

Fig 12: Identifying Shop Crane VAS 6100

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WARNING:

There is the risk of an accident if the support bridge parts are loose.

Install each threaded connection on the Lifting Eyebolt 3368 and the Slide Hammer Set - Adapter 40 VW771/40 until stop to make sure they are secure.
Secure the hooks and locking pins on the Engine Sling 2024A with cotter pins.

-- Lower the transmission intermediate housing into the transmission housing slowly and carefully.

Fig 13: Inserting Front Final Drive Oil Guide Into Transmission Housing

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CAUTION:

There is a danger of damaging the Sensor Module --.

When installing the transmission intermediate housing, pay close attention that the Sensor Module -- is not on the oil guide -1- and will not be damaged.

There is a risk of damaging the shift fork seal, refer to OVERVIEW - TRANSMISSION -item 3- Gear Position Seal (See Figure).

When guiding the transmission intermediate housing pay special attention not to contact the shift fork seal.

-- When lowering the transmission intermediate housing guide it so that the connector -1- from the Sensor Module -- is guided in the hole -arrow- on the transmission housing without tilting.

Fig 14: Installing Transmission Housing Connector

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NOTE:

The procedure from the transmission intermediate housing side is shown. The procedure from the transmission housing side must also be performed.

-- Guild the transmission intermediate housing completely on the transmission housing and secure it. Refer to Figure.

Fig 15: Mating Transmission Intermediate Housing To Transmission Housing

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-- Check if the connector retaining tabs for the sensor module are engaged in the transmission housing.

-- Connect the Sensor Module Tool T40228 flush with the connector housing for the Sensor Module --.

Fig 16: Mounting Connector Housing On Connector Using T40228

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NOTE:

The tabs for the Sensor Module Tool T40228 must securely mesh into the openings on the connector housing for the Sensor Module --.

-- Turn the connector housing with the Sensor Module Tool T40228 180° in the clockwise direction of -arrow- lock it into place.

-- Install the shaft seal for the separator in the transmission housing. Refer to TRANSMISSION HOUSING SEPARATOR SEALS, REPLACING .

-- Install the oil pump and the suction jet pump. Refer to OIL PUMP AND SUCTION JET PUMP, REMOVING AND INSTALLING .

NOTE:

The wiring set for the sensor module must be replaced when replacing the Sensor Module --.

Fig 17: Identifying Bolts -Arrows- On Wiring Set For Sensor Module

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Bolt tightening specification: position, refer to -item 38- Bolt (See Figure).

-- Tighten the bolts -arrows- on the wiring set for the sensor module.

-- Carefully press the connector on the Sensor Module -- completely opposite the direction of -arrow B-.

Fig 18: Carefully Press Connector On Sensor Module -- Completely Opposite Direction Of Arrow -Arrow B-

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-- Secure the fastener opposite the direction of -arrow A-.

-- Make sure that the connector is secured and fastened correctly on the Sensor Module --.

-- Tighten the bolt -1-.

NOTE:

Bolt tightening specification: position, refer to -item 38- Bolt (See Figure).

-- Mount the needle bearing -2- and spur gear -1- on the output shaft -3-.

Fig 19: Installing Spur Gear & Needle Bearing From Output Shaft

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-- Insert the side shaft -2- with the bolt -1- into the transmission intermediate housing.

Fig 20: Installing Bolt And Side Shaft

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-- Insert the side shaft -B- all the way onto the pinion and into the transmission cover.

Fig 21: Identifying Pinion Side Shaft Bolt

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Tighten the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the Counterhold - Side Shaft T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Tighten the Counterhold - Side Shaft T40217 on the transmission intermediate housing -arrows-.

Fig 22: Locating T40217 To Transmission Intermediate Housing

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-- Tighten the bolt for the side shaft.

-- Mount the oil guide for the input shaft -arrow-.

Fig 23: Installing Oil Guide For Input Shaft

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Installation is performed in reverse order of removal.

-- Install the center differential housing and the center differential. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING .

-- Install the DSG Transmission Mechatronic -J743-. Refer to MECHATRONIC, REMOVING AND INSTALLING .

-- Push the separator shaft seal in the transmission housing. Refer to TRANSMISSION HOUSING SEPARATOR SEALS, REPLACING .

-- Install the dual clutch. Refer to DUAL CLUTCH, INSTALLING .

-- Install the flywheel. Refer to FLYWHEEL, REMOVING AND INSTALLING .