Transmission, Installing: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Assembly Aid T40169
Transportation Lock T40170
Gearbox Support T40173
Engine-/Gearbox Jack V.A.G 1383 A Spindles 10 - 222 A /11
Counterhold Tool Touareg V 10T10172 with Adapter T10172/5
Ring Spanner Insert AF16 V.A.G 1332/14
Hose Clamps Up to 25 mm in Dia. 3094

Procedure

NOTE:

Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times.

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,

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.

Transmission installation tightening specifications TRANSMISSION, INSTALLING

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

Fig 1: Positioning V.A.G 1383 A And T40173 Under Transmission And Secure It With Tensioning Strap -1-

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-- Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate if necessary. Refer to the appropriate service information .

Fig 2: Checking Input Shaft For Scoring

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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 3: Ensuring Alignment Sleeves -A- For Centering Engine And Transmission In Cylinder Block Are Present

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See if it is possible to use the aluminum bolts -2 through 11- again and mark them if necessary TRANSMISSION, INSTALLING .

-- Installing the clutch module if necessary. Refer to Removal and Installation

Fig 4: Identifying Flywheel Components, Remove/Install

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

Fig 5: Inserting Assembly Aid T40169 Into Transmission Housing And Flywheel From Below

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-- Insert the T40169 in the transmission housing and the clutch module from below as shown in the illustration.

The T40169 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 clutch module as needed.

-- Install the bolts from the assembly device into the holes on the transmission housing.

-- Insert the T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 6: Identifying Transportation Lock T40170

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-- Raise the transmission straight up until the clutch slave cylinder -1- can be inserted.

Fig 7: Raising Transmission Straight Up Until Clutch Slave Cylinder Can Be Inserted

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-- Tighten the bolt -2-. Tightening specification -item 17- CLUTCH HYDRAULICS OVERVIEW .

NOTE:

The next step is only necessary if a drive plate with alignment pins -2- is installed.

Fig 8: Aligning Drive Plate To Clutch Module

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-- Also align the drive plate to the clutch module so the alignment pins -2- on the drive plate (if applicable) can engage in the larger holes -1- on the clutch module.

CAUTION:

The clutch will not function properly if it is not installed correctly.

The clutch may have noticeable function problems if the alignment pins for the drive plate -2- are not in the holes in the clutch module -1-.

-- Connect the transmission to the engine and tighten -3.... 11- the bolts. Tightening specifications TRANSMISSION, INSTALLING .

Fig 9: Engine To Transmission Bolts

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-- Install the starter and tighten the bolts -1 and 4-. Tightening specification TRANSMISSION, INSTALLING .

Fig 10: Disconnecting Starter Electrical Connector

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-- Raise the transmission using the V.A.G 1383 A until dimension -a- is reached between the subframe and the body.

Fig 11: Raising Transmission

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-a- = minimum 100 mm (3.93 inches)

-- Attach the push rod -1- -item 27- 27.

Fig 12: Identifying Bolts For Selector Rod And Push Rod

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-- Attach the connecting rod -3-. Tightening specification -item 25- 25.

-- Connect the connector -2- to the transmission range gear recognition switch -F208-.

-- Install the transmission shift lever -2- as follows:

Fig 13: Gearshift Lever Can Be Attached To The Gearshift Shaft In Only One Position

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The gearshift lever -2- can be attached to the gearshift shaft -1- in only one position (gap in the splines -arrow-).

-- Attach the transmission shift lever -2-. Tightening specification -item 18- 18.

-- Loosen the 10 - 222 A /11.

Fig 14: Identifying Additional Engine Support Bridge 10 - 222 A

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-- Lift the transmission and tighten the tunnel crossmember bolts -arrows-. Tightening specifications, refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Fig 15: Identifying Bolts & Tunnel Crossmember

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-- Remove the V.A.G 1383 A and T40173.

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

Fig 16: Identifying Left And Right Drive Axles

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-- Install the drive axle heat shield. Refer to Figure.

Fig 17: Drive Axle Heat Shield - Tightening Specification

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-- Install the driveshaft. Refer to Removal and Installation (0BC) or Removal and Installation (0BD) .

Fig 18: Counterholding Driveshaft Using T10172 And T10172/5

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Block the driveshaft. To do this, place the T10172 and T10172/5 on the driveshaft bolts on the transmission or the rear final drive.

Tightening Sequence - Clutch Module to the Drive Plate

Fig 19: Identifying Gearshift Assembly

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-- Remove the T40169 and T40170.

-- Remove the gearshift shaft -1- and then move the gearshift lever -2- forward in direction of -arrow- into 6th gear.

NOTE:

The following step is absolutely necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.

Fig 20: Locating Transmission Housing Check Hole

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-- Turn both front wheel together in one direction until the clutch module turns one complete turn (360°).

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

-- Tighten the clutch module to the drive plate as follows:

Fig 21: Identifying Clutch Module First Bolt Installation Location

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Use new bolts.
Tightening specification -item 3- CLUTCH MODULE OVERVIEW .
Tighten the bolts using the V.A.G 1332/14.

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

-- Turn the clutch module 180° in engine direction of rotation over both front gears.

-- Insert the second bolt and tighten it. Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

-- Install the remaining bolts and tighten them (and the one bolt that was installed earlier). Tightening specification -item 3- CLUTCH MODULE OVERVIEW .

Install in reverse order of removal. Note the following:

Fig 22: Pressing CV Joint Off Steering Gear And Slide It Up

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-- Tighten the universal joint on the steering gear. Refer to OVERVIEW - STEERING GEAR .

-- Install the driveshaft heat shield -A- and tighten the bolts -arrows- to 25 Nm, if equipped.

Fig 23: Identifying Transmission Heat Shield

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-- Install the right catalytic converter. Refer to the appropriate service information .

-- Install the left and right front muffler. Refer to the appropriate service information .

-- Install the exhaust system so that it is free of tension. Refer to the appropriate service information .

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

Fig 24: Identifying Subframe Crossbrace & Bolts

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-- Gear oil level in manual transmission, checking. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

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

-- Observe measures after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

Danger of causing damage to the control modules due to the excess voltage.

Do not use a charger to jump start!