Transmission, Installing

Transmission, Installing

Special tools, testers and auxiliary items required

• Ring Spanner Insert AF16 (V.A.G 1332/14)

• Assembly Aid (T40169)

• Transportation Lock (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, refer to the Parts Catalog.

• 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.

There are 2 different ATF filter versions depending on the engine and the date of manufacture. ATF pipe filter - 5 - and ATF filter - 10 -.






• ATF filter - 10 -, must be replaced at every ATF change or whenever a repair is made to the transmission.

• ATF pipe filter - 5 -, must be replaced whenever the transmission is replaced or if the ATF is very dirty. Refer to => [ ATF Pipe Filter ] ATF Pipe Filter.

Danger of damaging the components.

If a transmission with an ATF pipe filter - 5 - is replaced by a transmission with an ATF filter - 10 -.

• If the supply and return ATF pipe must be replaced, refer to => [ ATF Cooler, ATF Pipes, ATF Pipe Filter Overview ] ATF Cooler, ATF Pipes, ATF Pipe Filter Overview or => [ ATF Cooler, ATF Pipes and ATF Filter Overview ] Service and Repair. The ATF pipes are NOT the same. The ATF lines will leak or get damaged if they are not replaced.

• The ATF filter - 10 - must be changed at every ATF change in the future. Enter these in the vehicle data and in the repair history. The ATF filter change is not always automatically displayed in the maintenance schedule.

• If a transmission is installed with a replaceable ATF filter, make sure that a bleeder hose is also installed.

Check that the bleeder hose is installed correctly for vehicles with transmissions with replaceable ATF filters.






• The elbow of the bleeder hose - 2 - must be pressed onto the connection - 1 -.

- Press on the loose elbow until it audibly engages.

- Check that the base for both of the clamps - 4 - are correctly seated on the housing ribs - 5 -:

• The distance - a - from the rear clamp base to the housing flange must be 130 mm.

• The ATF breather pipe - 3 - must remain open.

All Vehicles

- Clean the ATF pipes and the ATF cooler after replacing the transmission or after repairing the transmission. Refer to => [ ATF Pipes and ATF Cooler, Cleaning ] ATF Pipes and ATF Cooler, Cleaning.

- Always clean the threaded holes for the engine/transmission bolts in the cylinder block before assembling the transmission using a thread cutter.








Danger of leaks in the ATF pan.

• The (T40173) must not be set on the ATF pan.

- Place the (V.A.G 1383 A) with the (T40173) under the transmission.

The transmission support must be placed at the front as follows:

• The bracket - 2 - fits into the 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 a tensioning strap - 1 -.






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






- Insert the (T40169) in the transmission housing and the clutch module from below, as illustrated.

• The assembly tool 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 flywheel as needed.

- Install the bolts from the assembly device into the holes on the transmission housing.

- Insert the (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.

- 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 then tighten the engine/transmission connecting bolts - 6 and 7 -.

- Install the tunnel crossmember. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.






• Shown without the (V.A.G 1383 A).

- Lower the (V.A.G 1383 A) and the (T40173) and move them to the side.

- Tighten then engine bolts to the transmission accessible from underneath.

- Remove the (T40170) and (T40169).

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






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

• Tighten the bolts with the (V.A.G 1332/14).

- Tighten the flywheel to the drive plate as follows:

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






- Insert the (T40058) guide pins as follows:






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the adapter.

- Continue turning the crankshaft on the vibration damper 180° in the direction of the engine rotation using the (T40058) - arrow -.






- Tighten the bolt with the crankshaft in this position. Refer to => [ Flywheel and Dual Clutch Overview ] Flywheel and Dual Clutch Overview.

- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to the tightening specification. Refer to => [ Flywheel and Dual Clutch Overview ] Flywheel and Dual Clutch Overview.

Install in reverse order of removal. Note the following:

- Attach the steering intermediate shaft to the steering gear.

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

- Install the ATF pipes. Refer to => [ ATF Pipes ] Service and Repair.

- 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 ].

• Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive repair manual.

- Install the driveshaft.

- Starter, install.

- Tighten the remaining engine/transmission connecting bolts - 3 through 5 -.






- Install the exhaust system free of tension.

- Install the plenum chamber bulkhead.

Vehicles with Hydraulic Power Steering

- Install the power steering hydraulic lines.

All Vehicles

- Install the subframe crossbrace.

- Install the diagonal braces.

- Install the drive axle covers and noise insulation.

- Complete the steps required after connecting the battery.

Danger of causing damage to the control modules due to the excess voltage.

• Do not use a charger to jump start!

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

Vehicles with Hydraulic Power Steering

- Fill the power steering fluid.

All Vehicles

- => [ ATF, Checking Level and Correcting ] ATF, Checking Level and Correcting.

- => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, 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 oil or transmission fluid 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 heat shield bolts - arrows - to 23 Nm.

S-Tronic Transmission to 6-Cylinder Engine











• The aluminum bolts - 2 through 10 - 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" may not be used again.