Transmission, Removing and Installing

Transmission, removing and installing, 01V, 5 SPD. A/T AWD

CAUTION: Before beginning repairs on the electrical system:
^ Obtain the anti-theft radio security code.
^ Switch the ignition off.
^ Disconnect the battery Ground (GND) strap.
^ On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.
^ After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.
^ After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar, switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

Transmission, removing and installing

Prepare the following special tools and test equipment for use:
^ 10-222 A engine support bridge
^ 10-222 AM Support
^ 10-222 A/3 Adapter
^ 10-222 A/12 Shackle
^ 80-200 pry lever for removing outside mirror
^ 3282 transmission support

^ 3282/19 adjustment plate
^ 3393 Testing Mandrels
^ 3457 Transport device
^ V.A.G 1306 drip tray
^ Engine/transmission support V.A.G 1383A engine/gearbox jack
^ VAS 5085 ladder

Removing

All:

Note:
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.

- First determine whether a coded radio is installed. If so, determine the correct coding.
See Caution before beginning repairs on the electrical system.
- Switch ignition off and disconnect battery Ground (GND) strap.

- Remove cover -1- in engine compartment (left side).

- Remove cover -1- in engine compartment (right side).

- Remove engine cover (arrows).
- Remove intake air duct from intake manifold.

- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1-.
- Remove bolts (arrows) and remove intake air guide -2-.

- Fit support bar 10-222A together with supports 10-222 AM and fit adapters 10-222 A/3.
- Secure spindles to engine. To do so, additionally use a shackle 10-222 A/12 at the front side of the engine to avoid damage.
- Take up weight of engine/transmission assembly on spindles.
- Loosen wheel bolts.
- Raise vehicle.
- Remove front wheels.

- Remove noise insulation panel (arrows).
- Remove front exhaust system with catalytic converter.

- Remove heat shields for left, if installed, and right drive axles (arrows).
Third bolt is not visible in the illustration.
- Unbolt left and right drive axles -1- from transmission flanges and tie up.

- Remove noise insulation bracket -1-.
- Disconnect connector -2- of wire for multi-function switch.
- Swing securing lever -3-, disconnect connector for transmission wiring harness.
- Cut cable ties -4-.
Make sure the wire for multi-function switch is not damaged when doing this.

- Disconnect connector from Speedometer Vehicle Speed Sensor (arrow -A-).

- Unbolt Engine Speed (RPM) Sensor -G28- (arrow -B-) from transmission.
- Unscrew nut -2- for clamp for ATF lines.
- Place V.A.G 1306 drip tray underneath.
- Always clean area of ATF line/transmission connection.
- Mark ATF lines if no color markings are present.

- Disconnect ATF lines -1-.
- Plug ATF lines with clean plug.
- Remove starter.

- Unbolt 3 torque converter bolts from drive plate (turn crank shaft an additional 1/3 turn every time).

- Remove heat shield for driveshaft at transmission (arrows).

- Unbolt driveshaft -1- on transmission and secure to panel -2- with wire (arrow).
- Remove shielding plate/selector lever cable, if installed.

- Mark position of mounting bracket for selector lever cable to transmission housing for re-installation, unbolt mounting bracket (arrow).
- Remove left transmission support with transmission mount.

- Pry off selector lever cable from lever/shift rod using 80-200 prying lever (arrows).

- Unbolt multi-function Transmission Range (TR) switch -F125- for protection against damage (arrows) and expose wiring harness.

- Prepare 3282 transmission support for Automatic Transmission 01V with 3282/10 adjustment plate and place it on the V.A.G 1383A engine/transmission hoist.

Note: The symbols on the adjustment plate indicate the necessary mounts for Automatic Transmission 01V and the arrow points toward front of vehicle.

- Roll V.A.G 1383A engine/transmission hoist with 3282 transmission support under transmission, align adjustment plate parallel to transmission and support transmission.
- Secure transmission on 3282 transmission support using bolt -A-.
- Fill space between gearbox support and sump with washers.
Automatic Transmission 01 V with All Wheel Drive is supported at the same positions as the Front Wheel Drive version.
- Remove right transmission support with transmission mount.

- Unclip retaining clip for coupling rods -1- of Left Front Level Control System Sensor -G78- from left front control arm -2-.

Vehicles with six-cylinder engine:
- Unbolt bolts (arrows) for stop/torque support -1-

All:
- Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.
- Remove nuts -1- on left and right engine mounts.

Note: When installing, make sure that locating sleeves -2- engage again.

- Before loosening subframe, check on both sides of vehicle, using 3393 Testing Mandrels, that at least holes -1- and -2- align.
If this is not the case, axle alignment must be carried out after tightening of subframe.
Hole -3- is not applicable here.

- Remove bolts -1- and -2- at rear of subframe on both sides of vehicle.
- Remove bolts -3- at front of subframe on both sides of vehicle.
- Remove bolts -4- (2 bolts at each vehicle side).
- Remove lower connecting bolts for engine/transmission.

- Lower engine-transmission-subframe using the spindles approximately 4 turns. To do this use Support VAS 5058.
- To do this lower engine/gearbox assembly using spindles in turn, 2 turns at a time.
- At the same time lower engine-transmission-subframe using lifter V.A.G 1383 A (second mechanic).

Note: When lowering transmission, ensure that no components are damaged.

- Remove upper connecting bolts for engine/transmission.
- Press transmission off engine, while pressing torque converter out of drive plate.

- Press torque converter against the ATF pump (arrow).
- Lower transmission.

- Secure converter so it does not fall out.
For disassembly and assembly, secure transmission to assembly stand using 3457 Transport device and VW 309 Holding plate.

Installing
Installation of transmission is the reverse of removal. The following points must also be observed:
Before installing:
- Clean threads in output flange/driveshaft flange using a tap.
- Clean ATF lines.
- Insert torque converter correctly into transmission

WARNING! In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF pump will be destroyed, if the transmission is flanged to the engine.

Installation dimension for torque converter, checking

When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approximately 23 mm.
If the torque converter is not inserted completely, this distance will be approximately 11 mm.
- Make sure bushings are correctly seated.

Note: If the bushings get stuck in the transmission housing, they must be removed and new bushings must be installed on the engine.

For 4 cylinder engines:
Item A = bushings

For 6 cylinder engines:
Item A = bushings

- Secure transmission on 3282 transmission support using bolt -A-.
- Move transmission into position between the lowered subframe and vehicle floor.
- Align transmission properly to engine.
- Tighten one engine/transmission connecting bolt at either side by hand.
- Make sure that wires do not get pinched as transmission is docked at engine.

WARNING! Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.

- Bolt together torque converter and drive plate.
- To do this insert bolts by hand and tighten to tightening torque.
- Insert top engine/transmission connecting bolts and tighten to tightening torque.

Note: Some bolts also have a bracket or a Ground (GND) connection attached.

- Raise engine-transmission-subframe using the spindles approximately 4 turns. To do this use Support VAS 5058.
- To do this raise engine/gearbox assembly using spindles in turn, 2 turns at a time.
- At the same time raise engine-transmission-subframe using lifter V.A.G 1383 A (second mechanic).

- Insert remaining engine/transmission connecting bolts and tighten to tightening torque
- Install subframe, observe tightening sequence and alignment with master bore hole.
- Only perform vehicle alignment if necessary.
- Install right transmission support with transmission mount

- Screw on lower nuts -A- on left and right engine mounts.

Vehicles with six-cylinder engine:
- Bolt on torque support stop -1- (arrows).

All:
- Attach retaining clip for coupling rods of Left Front Level Control System Sensor -G78- to left front control arm, if present.

- After subframe is installed, remove bolt -A- and remove transmission jack V.A.G 1383 A.
- Apply corrosion protection to contact surface between bolt -A- and oil pan.

- Push lever/selector shaft -2- on transmission fully forward (on illustration fully left).
- Shift selector lever into "S" and carefully press up ball head of selector lever cable -1- on lever/shift rod -2- using a pair of pliers.

Note: Do not deform lever/shift rod when pressing up or else shifting cannot be precisely adjusted any more.

- Bolt on mounting bracket for selector lever cable to transmission corresponding to marking for re-installation of transmission.
- Install shielding plate/selector lever cable, if present.

- Install Multi-Function Transmission Range (TR) Switch -F125-.
- Install left transmission support with transmission mount.
- Bolt driveshaft to transmission.

- Install heat shield for driveshaft at transmission (arrows).
- Install starter.

- Connect ATF lines -1- according to the respective color markings.

- Engage clamp for ATF lines and tighten nut -2-.

- Connect connector of Speedometer Vehicle Speed Sensor (arrow -A-).
- Bolt Engine Speed (RPM) Sensor -G28- (arrow -B-) to transmission.

- Install noise insulation bracket -1-.
- Connect connector -2- of wire for multi-function switch.
- Connect connector for transmission wiring harness and swivel securing lever-3-.
- Replace cable ties -4-.

- Bolt on left and right driveshafts -1- to transmission flanges.
- Install heat shields for left, if present, and right drive axles (arrows).
Third bolt is not visible in the illustration.
- Install front exhaust system with catalytic converter.

- Install noise insulation panel (arrows).
- Install front wheels.
- Remove 10-222A engine support bridge.
- Fit intake air duct to intake manifold.
- Install intake air guides.
- Install engine cover.
- Install left and right covers in engine compartment.
See Caution for connecting Telematics battery.
- After connecting battery, enter anti-theft code for radio.
go to Radio operating manual
- Check adjustment of selector lever cable.
- Check gear oil in front final drive with transmission installed.
- Then check ATF level and top off.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.