Transmission, Disassembling And Assembling: Installing

Tip

• By using the new Puller:T40436  the clutch does not need to be removed in general, but it can make it easier to mount the gear set.

-- Bring the gear actuator into the basic setting.

Courtesy of AUDI OF AMERICA, LLC

-- Push the gear actuator by hand and turn it at the same time 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 the gear set.

• If the gear set cannot be inserted, then remove the clutch. Refer to DUAL CLUTCH, REMOVING AND INSTALLING .

-- 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.

-- Position the new seal on the clutch housing and check if both centering pins are installed.

-- AWD vehicles: slide the Assembly Tool:T40367  -1- onto the transmission output shaft.

Courtesy of AUDI OF AMERICA, LLC

• Ignore -item 2-.
• The Assembly Tool:T40367  acts as an assembly aid when assembling the transmission housing.

TIP:

• To keep the joining forces low, coat the bearing areas with ATF before assembly.

-- Guide the transmission housing with the transmission.

Place the threaded spindle of the PullerT40436 into the input shaft.

-- Insert the threaded spindle -1- of the Puller:T40436  into the input shaft.

• The claws of the Puller:T40436  engage into the input shaft.

Bring the input shaft 3 in installation position

TIP:

• The Puller: T40436  can break if the tightening force is too high. The end stop has been reached when resistance is felt.

-- Attach the Puller:T40436  -1- sleeve into the transmission housing and the threaded spindle -arrow-.

-- Pull out the input shaft from the transmission housing over the nut -2-. At the same time counterhold on the hex fitting -arrow A- of the threaded spindle.

-- Install the new circlip -1- for the bearing "E".

Courtesy of AUDI OF AMERICA, LLC

• 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 Gearbox Assembly Tool: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.

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

TIP:

• Bolt -6- without centering sleeve.

-- Tighten the new bolts for the gear set -1 to 6- to 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 Press Tool:T40323  .

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

-- Fill the ATF. Refer to ATF, DRAINING AND FILLING .

-- Fill the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

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

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