Transmission, Disassembling And Assembling: Installing

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Vehicles with Self-Locking Center Differential

Courtesy of AUDI OF AMERICA, LLC

-- Check if the needle bearing -arrow- is installed.

Continuation for All Vehicles

Courtesy of AUDI OF AMERICA, LLC

-- Carefully insert gear set.

-- Evenly combine the bearing area and the gear actuator.

Vehicles with Self-Locking Center Differential

Courtesy of AUDI OF AMERICA, LLC

-- Install the needle bearing -arrow-.

Continuation for All Vehicles

Courtesy of AUDI OF AMERICA, LLC

-- Hand tighten the bolts -2- in the gear actuators -1-.

• When the gear positioner is installed correctly the dimension -X- is approximately 2 mm.

  Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts for the gear positioner to the tightening specification.

-- Install the Transmission Input Speed Sensor 1 -G632- and tighten the bolt -A-.

Courtesy of AUDI OF AMERICA, LLC

-- Install the wire in the bracket -B- at the same time pay attention to the correct routing.

-- Install the : T40213A  on the transmission.

Courtesy of AUDI OF AMERICA, LLC

Tip: 

• 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.

-- AWD vehicles: Slide : T40367  -1- onto the transmission output shaft.

Courtesy of AUDI OF AMERICA, LLC

-- Warm the inner race of the bearing "E" -arrow- with the : VAS1978/14A  to a maximum of 100 °C (212 °F).

Courtesy of AUDI OF AMERICA, LLC

-- Guide the transmission housing with the transmission.

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Tighten the bolts for the transmission housing to the tightening sequence. Refer to Figure.

Fig 1: Transmission Housing Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Push in the centering bracket -A- for the gear set all the way.

Fig 2: Gear Set Tightening Sequence (Transmission)

Courtesy of AUDI OF AMERICA, LLC

Tip: 

• Bolt -6- without centering sleeve.

-- Tighten the new bolts for the gear set -1 to 6- with the tightening sequence. Refer to Figure.

Vehicles without Self-Locking Center Differential

Courtesy of AUDI OF AMERICA, LLC

-- Install the oil catch tray -1-.

-- Press in the new end cover with the : T40323  .

Fig 3: Install the Caps for the Output Shaft -1-

Courtesy of AUDI OF AMERICA, LLC

Vehicles with Self-Locking Center Differential

Courtesy of AUDI OF AMERICA, LLC

-- Install the oil catch tray -1-.

-- Installing the self-locking center differential. Refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .

Continuation for All Vehicles

-- Dual Clutch, Installing. Refer to DUAL CLUTCH, REMOVING AND INSTALLING .

-- Fill with ATF. Refer to the appropriate service information. .

-- Fill the transmission fluid. Refer to the appropriate service information. .

-- If equipped, install the all wheel drive clutch. Refer to ALL WHEEL DRIVE CLUTCH, REMOVING AND INSTALLING .

-- Dispose the hydraulic pressure reservoir. Refer to HYDRAULIC PRESSURE RESERVOIR, DISPOSING .