Transmission, Installing, 2.0L TDI Engine

WARNING: This page is about a different car, the 2013 Audi A4, 2012 Audi A4, 2011 Audi A4, 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

Fig 1: Identifying Ring Spanner Insert AF 16 VAG 1332/14
Courtesy of AUDI OF AMERICA, LLC
Clutch Module Assembly Aid T40169

Fig 2: Assembly Aid T40169
Courtesy of AUDI OF AMERICA, LLC
Clutch Module Transportation Lock T40170

Fig 3: Identifying Transportation Lock T40170
Courtesy of AUDI OF AMERICA, LLC

Procedure

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.

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 4: Attach Exhaust System Retaining Strap Bracket To New Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Attach the exhaust system retaining strap bracket -1- to the new transmission. .

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

Fig 5: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

Courtesy of AUDI OF AMERICA, LLC

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

Fig 6: Insert Assembly Aid T40169 Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

-- 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 7: Identifying Transportation Lock T40170

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

Fig 8: Identifying Bolt & Spacer Sleeve

Courtesy of AUDI OF AMERICA, LLC

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 9: Engine To Transmission Bolts And Alignment Sleeves

Courtesy of AUDI OF AMERICA, LLC

-- 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 10: Identifying Torque Support And Bolts

Courtesy of AUDI OF AMERICA, LLC

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

All vehicles:

Fig 11: Identifying Bolts & Tunnel Crossmember

Courtesy of AUDI OF AMERICA, LLC

-- 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 12: Pressing Flywheel Slightly Against Drive Plate

Courtesy of AUDI OF AMERICA, LLC

-- 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 13: Identifying Offset Open-End Wrench

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

Fig 14: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

-- 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 DRIVE AXLE .

-- Install the driveshaft heat shield Figure.

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

Fig 15: Engine To Transmission Bolts And Alignment Sleeves

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

Fig 16: Identifying Bolt & Spacer Sleeve

Courtesy of AUDI OF AMERICA, LLC

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 OVERVIEW - SUBFRAME .

-- Install the diagonal braces. Refer to OVERVIEW - SUBFRAME .

-- Install the plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- Install the noise insulations. Refer to NOISE INSULATION .

-- Follow all steps after connecting the battery. Refer to CONNECTING - Battery .

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. Refer to GEAR OIL, CHECKING LEVEL .