Transmission, Installing

Special tools and workshop equipment required

Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14

Fig 1: Identifying Ring Spanner Insert AF 16 VAG 1332/14
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Clutch Module Transportation Lock:T40170

Fig 2: Clutch Module Transportation Lock T40170
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Cleaning Solution:D 009 401 04
Universal Adhesive: D 001 200 M2

Procedure

NOTE:

Replace the bolts that were tightened with an additional turn.

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

Secure all hose connections with hose clamps corresponding to series production. Refer to the appropriate Electronic Parts Information.

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

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF lines using compressed air (maximum 10 bar (145.04 psi)). Refer to 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 mount and the tunnel crossmember on the new transmission. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Position the Support: T90003 -2- on the Engine and Gearbox Jack:VAS6931 -1- with the mounting blocks under the transmission -4- and on the tunnel crossmember -5-.

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Mount the front bracket on the left transmission side behind the opening for the torque converter on the transmission housing.

-- Secure the transmission with the tensioning strap -3- on the Support:T90003 .

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 .

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

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

-- Attach the locking piece with Universal Adhesive:D 001 200 M2 on the lower timing chain cover at the same time pay attention to the instructions.

-- Bring the starter into the installation position.

-- 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 and transmission are in the cylinder block and insert them if they are not.

Fig 4: Engine to Transmission Bolts And Alignment Sleeves -A-

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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 an "X" made by a chisel after they have been used the first time -arrow-. .

NOTE:

When bringing together the engine and transmission make sure that the locking piece is seated correctly.

-- Place the engine on the transmission and at the same time install the bolt -1- for the starter.

Fig 5: Engine to Transmission Bolts And Alignment Sleeves -A-

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-- Tighten the bolts -2 through 11- by hand all the way.

-- Tighten the bolts -1 through 11-.

-- Remove the Tensioning Strap:T10038 and Engine Support Bridge - Special Hook (2 pc.):10-222A/20 .

-- Lift the transmission using the Engine and Gearbox Jack:VAS6931 and tighten the bolts for the tunnel crossmember. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Move the Engine and Gearbox Jack:VAS6931 with the Support:T90003 under the transmission.

All Vehicles:

Fig 6: Pressing Flywheel Slightly Against Drive Plate

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-- Remove the Clutch Module Transportation Lock:T40170 .

NOTE:

The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.

-- Push the torque converter -2- slightly against the drive plate -3- -arrow- using a pry bar -1-.

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

Fig 7: 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 shown.

NOTE:

There is only one notch on the circumference; rotate the torque converter as needed.

-- Tighten the bolt -arrow- for the torque converter -1- that is accessible in this position.

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Tightening specification 60 Nm

NOTE:

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

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CAUTION:

Danger of camshaft timing chain skipping.

Turn the crankshaft only in the direction of engine rotation -arrow-.

-- Counterhold the crankshaft to tighten the bolts for the torque converter with the Wrench - 21mm: T40263 and Adapter:T40314 .

-- Continue turning the crankshaft 60° and tighten the remaining five bolts -arrow- for the torque converter.

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Tightening specification 60 Nm

-- Tighten the remaining engine/transmission connecting bolts. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Install in reverse order of removal.

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

-- Install the ATF cooler. Refer to OVERVIEW - ATF CIRCUIT .

-- Install 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 front exhaust pipe and align the exhaust system free of tension. Refer to the appropriate Service Information .

-- Install the coolant pipe for the transmission. Refer to COOLANT PIPES, REMOVING AND INSTALLING (3.0L) , COOLANT PIPES, REMOVING AND INSTALLING (4.0L) .

-- Install side transmission mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Install the shield and subframe crossbrace. Refer to OVERVIEW - SUBFRAME .

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

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING Servicing 3.0L , ENGINE COVER Servicing 4.0L .

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

CAUTION:

There is a risk of destroying control modules due to the excess voltage.

Do not use a charger to jump start.

-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING (3.0L) , COOLANT, DRAINING AND FILLING (4.0L) .

-- Check the parking lock emergency release. Refer to EMERGENCY RELEASE FROM P .

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

Tightening Specifications

Refer to TRANSMISSION TIGHTENING SPECIFICATIONS
Refer to OVERVIEW - ATF CIRCUIT
Refer to OVERVIEW - FINAL DRIVE
Refer to OVERVIEW - ASSEMBLY MOUNTS
Refer to SHIFT MECHANISM
Refer to OVERVIEW - COOLANT VALVES (3.0L) , OVERVIEW - COOLANT VALVES (4.0L) .
Refer to OVERVIEW - ELECTRIC COOLANT PUMP (3.0L) , OVERVIEW - ELECTRIC COOLANT PUMP (4.0L) .