Transmission, Installing: Procedure

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NOTE:

Replace the bolts that were tightened with an additional turn.

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

Secure hose connections with hose clamps that correspond to the series production. Refer to the Parts Information.

During installation, all cable ties must be installed at the same location.

There is a normal >>clicking<< in the dual mass flywheel with "LuK" centrifugal pendulum absorber.

A >>clicking<< is heard when turning in direction of -arrows- the clutch module -A- approximately every 90°. This noise comes from shifting pendulum masses (centrifugal pendulum absorber) in the dual mass flywheel and is not a fault.

Fig 1: Turning Clutch Module -A- With Centrifugal Pendulum Absorber 90 Degrees (Clicking Noise Normal)

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

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

Fig 2: Insert Assembly Aid T40169 Into Transmission Housing

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-- Insert the :T40169  in the transmission housing and the flywheel from below as shown.

• The tool must grip into the semicircular hole and also in the hole -arrows A and B-.
  Fig 3: Inserting Clutch Module Assembly Aid T40169 Into Transmission And Dual Mass Flywheel

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-- Insert the :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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-- 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 may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-. .

Vehicles with Sealing Piece

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-- Clean the contact surface -1- on the lower timing chain cover and on the sealing piece -2- with Cleaning Solution: D 009 401 04  .

-- Bond the sealing piece with the lower timing chain cover:

Vehicles with 4-Cylinder Engine

Fig 5: Identifying Bolt & Spacer Sleeve

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-- Bring the starter into the installation position.

Vehicles with 4-Cylinder TFSI Engine or 6-Cylinder TDI Engine: 

Fig 6: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder FSI Engine)

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-- Check if that the alignment sleeves -A- for centering the engine and transmission are inserted in the cylinder block.

-- Place the transmission on the engine to do so guide the starter.

-- Tighten the bolt -8- hand-tight.

-- Install tunnel crossmember. Refer to OVERVIEW - SUBFRAME MOUNT .

-- Remove The Extractor. Refer to ENGINE SUPPORT, REMOVING AND INSTALLING .

-- Tighten the bolts -1 to 10-.

Vehicles with 4-Cylinder TDI Engine: 

Fig 7: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder TDI Engine)

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-- Check if that the alignment sleeves -A- for centering the engine and transmission are inserted in the cylinder block.

-- Place the transmission on the engine to do so guide the starter.

-- Tighten the bolt -7- by hand all the way.

-- Install tunnel crossmember. Refer to OVERVIEW - SUBFRAME MOUNT .

-- Remove the extractor. Refer to ENGINE SUPPORT, REMOVING AND INSTALLING .

-- Tighten bolts -1 through 9-.

All Vehicles: 

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

-- Remove the :T40170  .

Fig 8: Identifying Transportation Lock T40170

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NOTE:

If the vibration damper -1- does not lay flat on the drive plate, insert the :T40170  and turn the crankshaft another 360°.

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-- Install the first bolt -arrow-, tighten to 10 Nm, loosen and then tighten to 2 Nm (hand-tight).

-- Remove the :T40169  .

Fig 9: Insert Assembly Aid T40169 Into Transmission Housing

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-- Tighten the flywheel to the drive plate as follows:

Vehicle With 4-Cylinder Engine (Three Bolts): 

-- 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 the engine rotation with a large offset open-end wrench.

-- Install the next bolt in this crankshaft stub and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Turn the crankshaft another 120° in the direction of engine rotation and install the next bolt and tighten.

-- Turn the crankshaft another 120° in the direction of engine rotation and tighten the last bolt.

Vehicle With 6-Cylinder Engine (Six Bolts): 

-- Turn the crankshaft on the vibration damper 180° in the direction of engine rotation, install bolt -4- and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

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-- Turn the crankshaft another 60° in the direction of engine rotation, install bolts -5 and 6- and tighten.

-- Turn the crankshaft another 60° in the direction of engine rotation and tighten bolt -1-.

-- Turn the crankshaft another 60° in the direction of engine rotation, install bolts -2 and 3- and tighten.

All Vehicles 

-- Install the cover -1-.

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Install in reverse order of removal. Note The Following: 

-- Connections and routing. Refer to the appropriate Wiring Diagram(s).

-- Tighten the drive axles. Refer to OVERVIEW - DRIVE AXLE .

-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install The Drive Axle Cover. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER / FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Install the front wheels. Refer to WHEEL, CHANGING AND MOUNTING / WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Install the parking lock emergency release cable. Refer to PARKING LOCK EMERGENCY RELEASE CABLE, REMOVING AND INSTALLING .

-- Install The Coolant Pipe For The Transmission. Refer to COOLANT PIPES, REMOVING AND INSTALLING [CVKB, DBPA, CWNA, CVLA, DEMA, DHDA] .

-- Install the steering intermediate shaft. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to the appropriate service information. .

-- Install The Emissions Control Module. Refer to the appropriate service information (EMISSIONS CONTROL SYSTEM ). .

-- Install the front exhaust pipe. Refer to OVERVIEW - MUFFLER .

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

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING (2.0L TFSI) .

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Check the MTF level and correct if necessary. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Check the ATF level and correct if necessary. Refer to ATF LEVEL, CHECKING .

-- Connect the Vehicle Diagnostic Tester.

-- Select Diagnostic  mode and start the diagnostic.

-- Select the Test Plan  tab.

-- Select Individual Test  button and select the following tree structure one after the other:

• Drivetrain
• 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL
• 01  - OBD-capable systems
• 02  - Transmission electronics 0CK
• 02  - Transmission electronics, functions
• 02  - Replace control module → Entire transmission

-- Start the selected program and follow the instructions in the display of the Vehicle Diagnostic Tester.