Gear Set, Removing And Installing: Installing
-- Bring the gear positioner into the basic setting.
-- Push the gear positioner by hand and turn at the same time it until it engages and determine the current backlash.
Transmission with Self-Locking Center Differential:
-- Check if the needle bearing -arrow- is installed.
All Transmissions:
-- Carefully remove the gear set.
-- Guide together the bearing area and gear positioner -arrows- evenly.
Transmission with Self-Locking Center Differential:
-- Install the needle bearing -arrow-.
All Transmissions:
-- Install the gear positioner -arrows- hand-tight.
-- Tighten the bolts for the gear positioner to the tightening specification. Refer to OVERVIEW - GEAR SET, FWD VEHICLES .
-- Install the Transmission Input Speed Sensor 1 -G632- and tighten the bolt -A-. Refer to OVERVIEW - GEAR SET, FWD VEHICLES .
-- Install the wire in the bracket -B- at the same time pay attention to the correct routing.
-- Install the :T40213A on the transmission.
This step is necessity to that the bearing "E" in the transmission housing can be mounted correctly on the shaft.
-- Install the spindle from the :T40213A by hand until the input shaft has raised approximately 2 to 3 mm and there is a small resistance when turning.
-- Position the new seal and check if both centering pins are installed.
-- Warm the inner race of the bearing "E" -arrow- with the :VAS1978/14A to a maximum of 100° C (212 °F).
Risk of damaging the bearing seal.
- Only warm up the inner bearing race.
-- Guide the transmission housing with the transmission.
-- Install the new circlip -1- for the bearing "E".
The circlips have different installed dimensions.
If the bearing "E" is not replaced, a circlip with the same dimension as the old circlip must be installed.
For a new bearing "E" the largest possible circlip to be installed must be used.
-- Remove the :T40213A from the transmission.
-- Tighten the transmission housing with new bolts. Tightening sequence and tightening specification. Refer to OVERVIEW - TRANSMISSION, FWD VEHICLES .
-- Tighten the bolts for the transmission housing to the tightening sequence. Refer to illustration.
-- Tighten the bolts in three steps in the sequence shown:
| Step | Bolts | Tightening Specification |
|---|---|---|
| 1. | -1 to 9- | Install by hand evenly until the bolt head contact the transmission housing. |
| 2. | -1 to 9- | Tighten one after the other to 10 Nm + 90° |
| 3. | -Arrow- | Tighten the remaining bolts clockwise to 10 Nm + 90° |
-- Push in the centering bracket -A- for the gear set all the way.
Bolt -6- without centering sleeve.
-- Tighten the new bolts for the gear set -1 to 6- with the tightening sequence. Refer to Figure.
Transmission with FWD or All Wheel Drive Clutch
-- Install the oil catch tray -1-.
-- Press in the new end cover with the :T40323 .
Oil loss due to improper assembly.
- The end cover is installed "dry". Never use retaining compound.
- Let the end cover be tensioned 10 minutes with the :T40323 .
Transmission with Self-Locking Center Differential
-- Install the oil catch tray -1-.
-- Install the self-locking center differential/all wheel drive clutch:
Refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .
Refer to the appropriate service information. .
All Vehicles
-- Install the clutch. Refer to DUAL CLUTCH, REMOVING AND INSTALLING .
-- Fill the ATF. Refer ATF, DRAINING AND FILLING [7-SPEED DUAL CLUTCH TRANSMISSION] / TRANSMISSION FLUID, DRAINING AND FILLING [7-SPEED DUAL CLUTCH TRANSMISSION] / ATF LEVEL, CHECKING [7-SPEED DUAL CLUTCH TRANSMISSION] .
-- Fill the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING [7-SPEED DUAL CLUTCH TRANSMISSION] / ATF LEVEL, CHECKING [7-SPEED DUAL CLUTCH TRANSMISSION] .