Transmission, Installing

Transmission, Installing

Special tools, testers and auxiliary items required

• Ring Spanner Insert AF 16 (V.A.G 1332/14)

• Assembly Aid (T40169)

• Transport Lock (T40170)

• Transmission Support (T40173)

• Spindle (10 - 222 A /11)

• Engine/Transmission Jack (V.A.G 1383 A)

• Counter Hold Tool (T10355)

Procedure

• Replace bolts that are tightened to specification.

• Replace self-locking nuts and bolts and seals, gaskets and O-rings.

• Hose connections and charge air system 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. Refer to the Electronic Parts Catalog (ETKA).

• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

• When installing, bring all cable ties back to the same positions.

Transmission Installation Tightening Specifications:

- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar). Refer to => [ ATF pipes and ATF Cooler, Cleaning ] Service and Repair.

- 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, transmission mount and tunnel crossmember in the new transmission. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.






- Attach the exhaust system retaining strap bracket - 1 - to the new transmission.

- Mount the transmission onto the (T40173) and secure it using the tension strap - 1 - as illustrated.






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






- Insert the (T40169) in the transmission housing and the dual mass flywheel from below as shown in the illustration.

• The (T40169) must engage in the semi-circular opening - 1 - and into the check hole - 2 -.

• There is only 1 inspection opening on the circumference; rotate the dual mass flywheel as needed.

- Insert the (T40170) in the transmission housing from below and secure it on the flange shaft - 1 -.






- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.






- 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.

- Attach the transmission to the engine and tighten the bolts - 2 through 6 -.

• The bolt - 2 - attaches the starter to the transmission and has an additional spacer sleeve - arrow -.






• The spacer sleeve must be inserted between the starter and the transmission.

- Remove the (T40170) and (T40169).

- Loosen the (10 - 222 A /11).






- Raise the transmission and tighten the tunnel crossmember bolts - arrows -. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.






- Loosen the tension strap and remove the (V.A.G 1383 A) with the (T40173) from under the transmission.

• The following step is necessary to make sure the dual-mass flywheel rests on the drive plate evenly and is not tilted.






- Push the dual mass flywheel - 2 - slightly against the drive plate - 3 - using a pry bar - 1 - - arrow -.

- Tighten the dual-mass flywheel to the drive plate as follows:






- Install the first bolt - arrow - and tighten by hand (2 Nm).

- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the (T10355).






- With the crankshaft in this position, tighten the bolt - arrow - to 60 Nm.






- Continue turning the crankshaft 120° and tighten the remaining 2 bolts to the tightening specification.

Install in reverse order of removal paying attention to the following:






- Tighten the remaining bolts - 1, 7 to 11 - that attach the engine to the transmission.

- Attach the steering intermediate shaft to the steering gear.

- Install selector lever cable. Refer to => [ Selector Lever Cable ] Service and Repair.

- Install ATF lines. Refer to => [ ATF Pipe, ATF Cooler, and ATF Filter Overview ] Description and Operation.

- Attach the left and right drive axles to the transmission flange shafts.

- Install the drive axle heat shield. Refer to => [ Driveshaft Heat Shield - Tightening Specification ].

- Install the subframe crossbrace.

- Install the diagonal brace.

- Install the noise insulation.

- Be sure to follow the procedure for connecting the battery and afterwards.

There is a risk of destroying control modules with excess voltage.

• Do not use a charger as a starting aid.

- Check the selector lever cable and adjust if necessary. Refer to => [ Selector Lever Cable, Adjusting ] Adjustments.

- Check the ATF level and correct if necessary. Refer to => [ ATF, Checking Level and Correcting ] ATF, Checking Level and Correcting.

- After repairing the transmission, check the axle oil level in the front final drive and adjust if necessary. Refer to => [ Gear Oil Level in Front Final Drive, Checking and Filling ] Gear Oil Level In Front Final Drive, Checking and Filling.

Tightening Specifications

• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.

• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.

• Do not use any ungreased parts.

• Tightening specification tolerance +/- 15%.






Driveshaft Heat Shield - Tightening Specification





- Tighten the right heat shield driveshaft bolts - 1 - to 23 Nm.

Securing Engine to Transmission











• Audi A4 from VIN 8K-9A-066500, Audi A5 from VIN 8T-9A-008000: Aluminum bolts - 2 through 11 - may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time - arrow -.






• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.

• Bolts marked with an "X" may not be used again.