Transmission, Installing
Transmission, Installing
Special tools, testers and auxiliary items required
• Assembly Tool (T40169)
• Transport Protection (T40170)
Transmission installation tightening specifications:
Procedure
• Replace bolts that are tightened to the specification.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory.
• To secure the air guide hoses on their connections, spray the clamps used previously with rust remover before installing.
• When installing, bring all cable ties back to same positions.
• 6-cylinder engines only: Always clean the threaded holes for the engine/transmission bolts in the cylinder block before assembling the transmission using a thread cutter.
CAUTION!
Danger of leaks in the ATF oil pan.
• The Transmission Support (T40173) must not be set on the ATF oil pan.
- Place the Engine/Transmission Jack (V.A.G 1383 A) with the Transmission Support (T40173) under the transmission.
The transmission support must be placed at the front as follows:
• The bracket - 2 - fits into the dual-mass flywheel on the transmission housing on the left side of the transmission.
• The transmission support is installed with an elastic washer - 1 - on the center differential housing on the right side of the transmission.
- Secure the transmission with the tensioning belt - 1 -.
- The following preparations must be made before connecting the engine and transmission:
- Insert the Assembly Tool (T40169) in the transmission housing and the dual mass flywheel from below as shown in the illustration.
• The assembly tool must engage in the semi-circular opening - 1 - and the inspection opening - 2 -.
• There is only 1 inspection opening on the circumference; rotate the dual mass flywheel as needed.
- Install the bolts from the assembly device into the holes on the transmission housing.
- Insert the Transport Protection (T40170) in the transmission housing from below and secure it on 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.
Vehicles with 2.0L TFSI engine:
- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.
- Connect the transmission to the engine and tighten the bolts - 6 - and - 7 -.
Vehicles with 2.0L TDI engine:
- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.
- Connect the transmission to the engine and tighten the bolts - 6 - and - 7 -.
Vehicles with 3.2L FSI and 3.0L TDI engine:
- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.
- Connect the transmission to the engine and tighten bolts - 6 - and - 7 -.
All Vehicles
- Install the tunnel crossmember. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Assembly Overview ] 0B5A Automatic Transmission.
• The Engine/Transmission Jack (V.A.G 1383 A) is not shown in the illustration.
- Lower the Engine/Transmission Jack (V.A.G 1383 A) and the Transmission Support (T40173) and move them to the side.
- Tighten then engine bolts to the transmission accessible from underneath.
- Remove the Transport Protection (T40170) and Assembly Aid (T40169).
• The following step is necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.
- Press the clutch module - 2 - against the drive plate - 3 - slightly in direction of - arrow - using an assembly lever - arrow -.
Vehicles with 2.0L TFSI and 2.0L TDI engine:
- Tighten the clutch module to the drive plate as follows:
- Install first bolt - arrow - and tighten by hand (2 Nm).
- Turn the crankshaft on the vibration damper 240° in the direction of engine rotation.
- With the crankshaft in this position, tighten the bolt to the tightening specification. Refer to => [ Dual Mass Flywheel and Dual Clutch Assembly Overview ] Dual Mass Flywheel and Dual Clutch Assembly Overview.
- Continue turning the crankshaft 120° and tighten the remaining 2 bolts to the tightening specification. Refer to => [ Dual Mass Flywheel and Dual Clutch Assembly Overview ] Dual Mass Flywheel and Dual Clutch Assembly Overview.
• Pay no attention to - arrow -.
Vehicles with 3.2L TFSI and 3.0L TDI engine:
- Tighten the clutch module to the drive plate as follows:
- Install the first bolt - arrow - and tighten by hand (2 Nm).
- Insert the Adapter (T40058) guide pins as follows:
• The larger diameter - arrow 1 - faces toward the engine.
• The small diameter - arrow 2 - faces toward the adapter.
- Continue turning the crankshaft on the vibration damper 180° in the direction of the engine rotation using the Adapter (T40058) - arrow -.
- With the crankshaft in this position, tighten the bolt to the tightening specification. Refer to => [ Dual Mass Flywheel and Dual Clutch Assembly Overview ] Dual Mass Flywheel and Dual Clutch Assembly Overview.
- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification. Refer to => [ Dual Mass Flywheel and Dual Clutch Assembly Overview ] Dual Mass Flywheel and Dual Clutch Assembly Overview.
All Vehicles
Further installation in reverse order, paying attention to the following:
- Tighten the universal joint on the steering gear. Refer to => Suspension, Wheels, Steering 48 Description and Operation.
- Install selector lever cable. Refer to => [ Selector Lever Cable ] 0B5A Automatic Transmission.
- Install ATF lines. Refer to => [ ATF Cooler, ATF Pipes and ATF Filter Assembly Overview ] 0B5A Automatic Transmission.
- Install the left and right drive axles on the transmission flange shafts.
- Install the drive axle heat shield => [ Tightening specification, drive axle heat shield ]
- Install the driveshaft.
Vehicles with 2.0L TFSI and 2.0L TDI engine:
• The bolt - 2 - attaches the starter to the transmission and has an extra spacer sleeve - arrow -.
• The spacer sleeve must be inserted between the starter and the transmission.
All Vehicles
- Install the starter.
- Tighten the remaining bolts - 3 through 5 -, which connect the transmission to the engine.
- Re-assemble the exhaust system and ensure it is not under stress. Refer to => Engine Mechanical 26 Description and Operation.
- Install the power steering hydraulic oil lines. Refer to => Suspension, Wheels, Steering 48 Description and Operation.
- Install the subframe crossbrace.
- Install the covers for the drive axle and noise insulation. Refer to => Body Exterior 66 Description and Operation.
- Fill the power steering with hydraulic oil.
- Observe measures after connecting battery.
CAUTION!
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
- Check and adjust selector lever cable. Refer to => [ Selector Lever Cable, Adjusting ] Selector Lever Cable, Adjusting.
- Refer to => [ ATF, Checking Level and Correcting ] Procedures.
- Refer to => [ Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling ] Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling.
Tightening specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use degreased parts.
• Tolerance for tightening specification ± 15%.
Tightening specification, drive axle heat shield
- Tighten the drive axle heat shield bolts - arrows - to 23 Nm.
DSG transmission to 2.0L TFSI
DSG transmission to 3.2L FSI
DSG transmission to 2.0L TDI engine
DSG transmission to 3.0L TDI engine
• The aluminum bolts - 2 through 10 - may be used two times. After using the bolts once, mark them with an "X" made with a chisel - arrow -.
• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a 1/2" drive which is inserted in the vise, as shown in the illustration.
• Do not reuse bolts marked with an "X".