Transmission, Installing, 3.2L FSI

WARNING: This page is about a different car, the 2010 Audi A4 and 2009 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
Clutch Module Transportation Lock T40170

Procedure

NOTE:

Replace any bolts that were tightened with an additional turn.

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.

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar (145 psi)). 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 .

-- Mount the transmission onto the Gearbox Support T40173 and secure it using the tension strap -1- as illustrated.

Fig 1: Mount 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 2: Locating Hole Next To Notch

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-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as illustrated.

NOTE:

There is only 1 notch on the circumference; rotate the torque converter as needed.

-- Insert the Clutch Module 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: 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. Refer to MOUNTING THE TRANSMISSION TO THE 3.2L FSI ENGINE .

-- Coat locking piece -1- with lubricant.

Fig 5: Identifying Locking Piece

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-- Bring the starter -1- with the locking piece -2- into the installed position -4- by supporting the starter on the engine bracket using a plastic or rubber wedge -3-.

Fig 6: Starter, Locking Piece, Wedge And Installed Position

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NOTE:

In this assembly overview pay attention, that the locking piece are in the correct installed position with the starter, if not the starter support bolts are difficult to install and the locking piece will no longer have its sealing capability.

NOTE:

There are different versions of the locking piece depending on the engine.

-- Place the transmission on the engine and tighten the bolts -6 through 11- that connect the engine to the transmission.

Fig 7: Engine To Transmission Bolts

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-- Fasten the starter with the bolts -1 and 2- while doing so make sure the locking piece fits correctly.

-- Remove the Clutch Module Transportation Lock T40170.

-- Loose the Engine Support Bridge - Spindle 10-222A/11

Fig 8: Identifying Additional Engine Support Bridge 10 - 222 A

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-- Raise the transmission and tighten the tunnel crossmember bolts -arrows-. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 9: Identifying Tunnel Crossmember

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-- 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 torque converter rests on the drive plate evenly and is not tilted.

Fig 10: Pressing Torque Converter

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-- Press the torque converter -2- against the drive plate -3- slightly in the direction of the -arrow- using an assembly lever -1-.

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

Fig 11: Identifying Clutch Module First Bolt Installation Location

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NOTE:

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

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

-- Insert the Crankshaft Socket T40058 guide pins as follows:

Fig 12: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Continue turning the crankshaft 180° in the direction of the engine rotation using the Crankshaft Socket T40058 -arrow-.

Fig 13: Identifying TDC With Special Tool Adapter T40058

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

Fig 14: Identifying Clutch Module First Bolt Installation Location

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-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to 60 Nm.

-- Tighten the remaining bolts -3 through 5-.

Fig 15: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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Install in reverse order of removal. Note the following:

Fig 16: Press CV Joint Off Steering Gear And Slide It Up

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-- Attach the steering column to the steering gear. Refer to OVERVIEW - STEERING COLUMN .

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

-- Install selector lever cable. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

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

-- Tighten the left and right drive axle on the transmission flange shafts. Refer to OVERVIEW - DRIVE AXLE .

-- Install the driveshaft heat shield. Refer to Figure.

-- Install the driveshaft. Refer to OVERVIEW - DRIVESHAFT for Rear Final Drive 0BC, 0BD, 0BE, 0BF, or 39 FINAL DRIVE, DIFFERENTIAL for Rear Final Drive 0BF and 0BE - Sport Differential .

-- Reconnect exhaust system making sure it is not under stress. Refer to EXHAUST PIPES/MUFFLERS .

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

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of destroying control modules due to the 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 .