Transmission, Installing

Special tools and workshop equipment required 

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

Procedure 

-- 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: 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 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.

-- 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.

-- 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 .

-- Attach the transmission to the engine and the tighten the bolts -1 and 6 through 11-.

Fig 4: Identifying Transmission To Engine Bolts And Alignment Sleeves

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-- Remove the Clutch Module Transportation Lock T40170.

-- Loose the Engine Support Bridge - Spindle10-222A/11

Fig 5: 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 6: Identifying Crossmember & Bolts

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-- Loosen the tensioning strap and guide the Engine and Gearbox Jack VAS6931 with the Gearbox Support T40173 under the transmission.

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

Fig 7: Pressing Torque Converter Up Against The Drive Plate

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

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

Fig 8: Identifying Clutch Module Starter Bolt -1-

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

Fig 9: 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 in direction of -arrow-.

Fig 10: 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 11: Identifying Clutch Module Starter Bolt -1-

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

-- Tighten the remaining bolts -2 through 5-.

Fig 12: Identifying Transmission To Engine Bolts And Alignment Sleeves

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Install in reverse order of removal. Note the following:

Fig 13: Locating Universal Joint Bolt

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-- Attach the universal joint to the steering gear, refer to OVERVIEW - STEERING COLUMN .

-- Install the subframe crossbrace, refer to INSTALLING .

Fig 14: Locating Power Steering Hydraulic Line

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-- 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 axles on the transmission flange shafts, refer to INSTALLING , also see OVERVIEW - WHEEL BEARING HOUSING AND WHEEL BEARING UNIT -item 22-.

-- Install the drive axle heat shield, refer to Figure.

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

-- Reconnect exhaust system making sure it is not under stress, refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

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

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