Transmission, Installing
Transmission, Installing
Special tools, testers and auxiliary items required
• Ring Spanner Insert AF16 (V.A.G 1332/14)
• Transportation Lock (T40170)
Procedure
• Replace bolts that are tightened to the specification. Aluminum bolts used for attaching the transmission to the engine may be used one time only.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the electronic parts catalog ETKA.
• When installing, bring all cable ties back to 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 => [ Automatic Transmission Fluid Lines, 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, the transmission mounting and the tunnel crossmember on the new transmission. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.
- Mount the transmission onto the transmission support (T40173) and secure it using the tension strap - 1 - as illustrated.
- The following preparations must be made before connecting the engine and transmission:
- Turn the torque converter so that the hole next to the notch - arrow - is visible in the lower cut-out in the transmission housing as illustrated.
• There is only 1 notch on the circumference; rotate the torque converter as needed.
- Insert the transportation lock (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 the tighten the bolts - 6 through 11 -.
- Remove the transport protection (T40170).
- 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 engine/transmission jack (V.A.G 1383 A) with the transmission support (T40173) from under the transmission.
- Clip the locking piece - 1 - into the starter opening.
• Make sure locking piece - 1 - is installed correctly before installing the starter - arrows -.
• Apply some grease to the locking piece if it is difficult to install the starter.
- Install the starter. While doing this, install the spacer - arrow - on the bolt - 2 - between the starter and the transmission.
• The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.
- Press the torque converter - 2 - against the drive plate - 3 - slightly in the direction of the - arrow - using an assembly lever - 1 -.
- Attach the torque converter to the drive plate as follows:
• Use the ring spanner insert AF16 (V.A.G 1332/14) to tighten.
- 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 counter hold tool (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.
- Tighten the remaining engine/transmission connecting bolts - 3 through 5 -.
• The bolts - 3 - and - 5 - also attach the wire bracket on the transmission.
Install in reverse order of removal paying attention to the following:
- Install the ATF pipes. Refer to => [ ATF Pipes ] ATF Pipes.
- Attach the selector lever cable to the transmission. Refer to => [ Selector Lever Cable ] Removal and Replacement.
- Attach the steering column to the steering gear.
- Attach the left and right drive axles to the transmission flange shafts.
- Install the subframe crossbrace.
- Install the drive axle right heat shield.
- Install the right subframe shield under the right drive axle.
- Install the driveshaft.
- Install the exhaust system free of tension.
- Install the noise insulation.
- Be sure to follow the procedure for connecting the battery 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.
Tightening specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.
• Do not use any ungreased parts.
• Tightening specification tolerance: ± 15%.
Other tightening specifications:
Driveshaft Heat Shield - Tightening Specification
• Depending on the date of manufacture, an additional drive axle heat shield - B - may be attached.
• The shape of the additional heat shield depends on the engine and on the date of manufacture.
• Mark the installed position of the additional heat shield - A - before removing it.
- Note the marking when installing the heat shield - B -.
- Tighten the drive axle heat shield bolts - 1, 2 and 3 - to 23 Nm.
Mounting Transmission to Engine
• The aluminum bolts - 2 through 11 - can be used 2 times. 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 cannot be used any further.