Transmission, Installing

Special tools and workshop equipment required 

• Clutch Module Transportation Lock:T40170 
• Gearbox Support:T40173 
• Engine and Gearbox Jack:VAS6931 
• Locating Pins for Steering Box:T40334 
• Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14 
• As well as all the special tools listed for the removal.

Procedure

• 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 appropriate 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 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 .

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

-- Before installing the transmission, check the installed dimension of the torque converter. Refer to TORQUE CONVERTER, REMOVING AND INSTALLING .

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

-- 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.

• There is only 1 notch on the circumference; rotate the torque converter as needed.

-- Insert the Clutch Module Transportation Lock:T40170  from below into the transmission housing and secure it to the flange shaft -1-.

-- 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 .

-- Always clean the threaded holes for the engine/transmission bolts in the cylinder block before assembling the transmission using a thread cutter.

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:

All Vehicles:

-- Bring the starter into the installation position.

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

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

-- Place the transmission on the engine by guiding the starter and installing the starter bolt -1- at the same time.

-- Install tunnel crossmember. Refer to TUNNEL CROSSMEMBER, REMOVING AND INSTALLING .

A4/A5/Q5 with 3.0L TFSI Engine:

-- Tighten the bolts -1 through 11-.

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

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A4/A5 with 3.0L TDI Engine:

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-- Support the steering gear -2- with a foam mat -1- placed between it and the :VAS6931  .

-- Remove the Locating Pins for Steering Box :T40334  on the left and right side.

-- Lower the steering gear and push slightly forward.

-- Tighten the bolts -1 and 11-.

-- Bring the steering gear back into the installation position and secure with the :T40334  .

-- Remove the extractor. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION (2.0L) , ENGINE, SUPPORTING IN INSTALLATION POSITION (3.0L) .

-- Tighten the bolts -2 through 10-.

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

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Q5 with 3.0L TDI Engine:

-- Remove the Tensioning Strap:T10038  .

-- Tighten the bolts -1 to 10-.

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

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All Vehicles:

-- Remove the :T40170  .

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

-- Press the torque converter -2- against the drive plate -3- slightly in direction of -arrow- using an assembly lever -1-.

-- Tighten the torque converter -1- as follows to the drive plate -arrow-  :

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• Use the :VAG1332/14  to tighten the bolts.

-- Install the first bolt -1- and tighten to 10 Nm, loosen and then tighten to 2 Nm (hand-tight).

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

-- 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.

-- Install the cover -1-.

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Install in reverse order of removal.

-- Install the ATF cooler. Refer to ATF COOLER, REMOVING AND INSTALLING .

-- Install the subframe shield. Refer to SUBFRAME SHIELD, REMOVING AND INSTALLING .

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

-- Connections and routing. Refer to the appropriate Wiring Diagram.

-- 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 .

-- Install the front wheels. Refer to WHEELS AND TIRES .

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

-- Install the coolant pipes. Refer to OVERVIEW - COOLANT PIPES (2.0L) , OVERVIEW - COOLANT PIPES (3.0L) .

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

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

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING (2.0L) , CATALYTIC CONVERTER, REMOVING AND INSTALLING (3.0L) , or install the emissions control module. Refer to the appropriate Service Information .

-- Install the front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING (2.0L) , FRONT MUFFLER, REMOVING AND INSTALLING (3.0L) or install the front exhaust pipe. Refer to the appropriate Service Information .

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

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

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

• If a new factory transmission is installed, an ATF level test is not necessary.
• If the transmission is replaced, the "Replace control module" function must be performed using the Vehicle Diagnostic Tester.

Procedure

-- 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
• 8-Speed Automatic Transmission 0D5
• 01 - OBD-capable systems
• 02 - Transmission electronics 0D5
• 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.