Transmission, Installing

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Special tools and workshop equipment required

Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
Crankshaft Socket T40058 for vehicles with 6-cylinder TFSI engine
Clutch Module Transportation Lock T40170
Crankshaft Turning Tool T40257 for vehicles with 6-cylinder TDI engine
Wrench - 21mm T40263 for vehicles with 6-cylinder TDI engine
Adapter T40314 for vehicles with 6-cylinder TDI engine

Procedure

NOTE:

Replace the bolts that were tightened with an additional turn. Aluminum bolts used for attaching the transmission to the engine may be used one time only, refer to TRANSMISSION TIGHTENING SPECIFICATIONS . The aluminum bolts -2 through 11- may be reused twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-, (See Figure)

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

Secure all hose connections with hose clamps, refer to the Parts Catalog.

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 .

Fig 1: Gearbox Support T40173 (New Version Has Chrome Plated Parts)

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Before using the Gearbox Support T40173 always check if it meets the requirements.

The older version mounts, should not be used and should be replaced.

Characteristics (Newer Version)

On the newer version the components illustrated -red- are -yellow - chrome plated.

If the mount does not comply with corresponding specifications, proceed as follows:

Market Germany: Contact the company Matra for an exchange.
Markets (word wide except Germany): Contact your tool supplier for an exchange.

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

Fig 2: Securing Transmission With Tensioning Strap

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Installing the torque converter incorrectly can cause damage to the ATF pump drive plate.

Check the installed dimension of the torque converter, refer to TORQUE CONVERTER, REMOVING AND INSTALLING .

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

-- 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.

Fig 3: Locating Hole Next To Notch

Courtesy of AUDI OF AMERICA, LLC

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 4: 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 5: Engine To Transmission Bolts

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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 TRANSMISSION TIGHTENING SPECIFICATIONS . The aluminum bolts -2 through 11- may be reused twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-, (See Figure).

-- Coat locking piece -1- with lubricant.

Fig 6: 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 7: Starter, Locking Piece, Wedge And Installed Position

Courtesy of AUDI OF AMERICA, LLC

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.

Vehicles with 4-Cylinder Engine

Fig 8: Identifying Bolt & Spacer Sleeve

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-- Install the upper starter bolt -2- in the transmission.

-- Install spacer sleeve -arrow- on the bolt -2-.

All Vehicles

Fig 9: Engine To Transmission Bolts

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-- Position the transmission on the engine and tighten the bolts -6 through 11-.

-- 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.

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

Fig 10: Identifying Crossmember & Bolts

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-- Loosen the tensioning strap and guide the Engine/Gearbox Jack VAG1383A 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 11: Pressing Torque Converter

Courtesy of AUDI OF AMERICA, LLC

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

-- Turn the crankshaft on the vibration damper 360° in the direction of engine rotation.

Vehicles with a 2.0L TFSI Engine

Fig 12: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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Vehicles with 6-Cylinder TDI Engine

Fig 13: Identifying Wrench - 21 MM T40263

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Vehicles with 6-Cylinder TFSI Engine

Fig 14: Identifying TDC With Special Tool Adapter T40058

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14 to tighten the bolts.

-- 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).

Fig 15: Identifying Clutch Module First Bolt Installation Location

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Vehicle with 4-Cylinder Engine (3 bolts)

-- 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.

Vehicle with 6-Cylinder Engine (6 bolts)

-- 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.

All Vehicles

Fig 16: Engine To Transmission Bolts

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

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

Install in reverse order of removal. Note the following:

-- Install the ATF pipes, refer to ATF CIRCUIT .

-- Attach the selector lever cable to the transmission, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Attach the steering column to the steering gear, refer to OVERVIEW - STEERING COLUMN -item 18-. .

Fig 17: Locating Universal Joint Bolt

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-- Tighten the left and right drive axles on the transmission flange shafts, refer to OVERVIEW - WHEEL BEARING HOUSING AND WHEEL BEARING UNIT -item 22- .

-- Install the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

Fig 18: Locating Power Steering Hydraulic Line

Courtesy of AUDI OF AMERICA, LLC

-- Install the driveshaft right heat shield, refer to Figure.

-- Remove the right subframe shield underneath the right drive axle, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING

-- Install the driveshaft, refer to OVERVIEW - DRIVESHAFT and DRIVESHAFT, REMOVING AND INSTALLING .

-- Reconnect exhaust system making sure it is not under stress, refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION for CAEB, CPMB and CPMA, EXHAUST SYSTEM, INSTALLING WITHOUT TENSION for CPNB or EXHAUST SYSTEM, INSTALLING WITHOUT TENSION for CTUC and CTUD. .

-- Install the noise insulations, refer to OVERVIEW - NOISE INSULATION .

-- Follow all steps after connecting the battery, refer to battery - CONNECTING .

CAUTION:

Danger of causing damage to the 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 .