Mounting Double-Clutch Transmission

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WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
→ Secure components to prevent them from falling down.

Check whether input shaft is fitted with a circlip on the double-clutch shaft splines. If not:
1. 1.1 Coat shaft splines -3- with mounting paste (see PET).
2. 1.2 Carefully fit input shaft -1- until circlip -2- engages -Arrow- .
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Input shaft
Suspend transmission using > VAS 6100 - workshop crane and > 9932 - transmission mount-1- and position it on the engine.

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Workshop crane with lifting tackle 9932
Fit transmission on engine and screw in and tighten new screws. Observe specified tightening sequence.
Screws -1 to 5- > Initial tightening 20 Nm (15 ftlb.) + > Torque angle 60°

Screws -6 to 9- > Initial tightening 15 Nm (11 ftlb.) + > Torque angle 105°

Fig 1: Transmission Flange Screws Tightening Sequence
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Tightening sequence for transmission flange
Fit ATF line -2- and connect cable plugs -4 and 5- .
1. 4.1 Remove sealing plugs.
2. 4.2 Guide ATF lines -2- into transmission -6- and fit and tighten screw -1- .
  > Tightening torque 20 Nm (15 ftlb.)
3. 4.3 Fit and tighten screw -3- .
  > Tightening torque 8 Nm (6 ftlb.)
4. 4.4 Connect and secure cable plugs -4 and 5- on transmission -6- on both sides.
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ATF line and transmission plugs
Fit B+ line -1- and terminal 50 line -6- .
1. 5.1 Route B+ line -1- with terminal 50 line -6- and clip it in at fastening points -4- .
2. 5.2 Screw on B+ line -1- at the generator.
  1. 5.2.1 Fit and tighten nuts -2- .
    > Tightening torque 20 Nm (15 ftlb.)
  2. 5.2.2 Fit cover -3- .
3. 5.3 Connect cable plug for terminal 50 -5- .
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B+ line

For all-wheel drive vehicles:

6.1 Replace circlip -1- and O-ring -2- on input flange on all-wheel final drive.

6.1.1 Clean input flange -Arrow- on all-wheel final drive and connecting shaft at the splines and coat lightly with new mounting paste (see PET).

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Circlip and O-ring on all-wheel flange

6.2 Install connecting shaft -3- .

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Using impact puller 9799

6.2.1 Fit connecting shaft -3- on the all-wheel final drive and install using > 9799 - impact puller-1-Arrow- .

6.3 Check installation position of connecting shaft -1- . The connecting shaft is fitted correctly if groove -2- is visible.

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Groove in connecting shaft

6.4 Remove > 9799 - impact puller from the connecting shaft.