Transmission, Installing, 2.7L/3.0L TDI Engine

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

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• Clutch Module Assembly Aid T40169
  Fig 2: Assembly Aid T40169

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• Clutch Module Transportation Lock T40170
  Fig 3: Identifying Transportation Lock T40170

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• Crankshaft Turning Tool T40257
  Fig 4: Identifying Turning Over Tool T40257

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• Wrench - 21mm T40263
  Fig 5: Identifying Wrench 21 mm T40263

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• Adapter T40314
  Fig 6: Adapter T40314

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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 7: 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. .

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

Fig 8: 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 9: 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 T40169must 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 10: 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 11: 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 12: 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 13: Identifying Wrench - 21 MM T40263

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

Fig 14: 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 15: 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 DRIVE AXLE .

-- Install the driveshaft heat shield Figure.

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

Fig 16: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Install the particulate filter and the front exhaust pipe. .

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

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

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

-- Follow all steps after connecting the battery. Refer to 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. Refer to GEAR OIL, CHECKING LEVEL .