Transmission, Installing: Procedure

NOTE:

Replace the bolts that were tightened with an additional turn.

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 Parts Information

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

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar (145 psi)). Refer to Clean .

-- 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 ASSEMBLY MOUNTS OVERVIEW .

-- Mount the transmission onto the Gearbox Support:T40173 and secure it using the tension strap -1- as illustrated.

Fig 1: Securing Transmission With A Tensioning Strap

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CAUTION:

Installing the torque converter incorrectly can cause damage to the ATF pump drive plate.

Check the installed dimension of the torque converter. Refer to 32 TORQUE CONVERTER .

-- 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. Refer to Mounting, Transmission toe 6.3L FSI Engine => The aluminum bolts may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-. .

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

Fig 2: Locating Hole Next To Notch

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-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as illustrated.

NOTE:

There is only 1 notch on the circumference; rotate the torque converter as needed.

-- Insert the Clutch Module Transportation Lock:T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 3: Identifying Transportation Lock T40170

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

-- Coat locking piece -1- with lubricant.

Fig 4: Identifying Locking Piece

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-- Bring the starter -2- with the locking piece -1- into the installed position -3- by supporting the starter on the engine bracket using a plastic or rubber wedge -4-.

Fig 5: Starter, Locking Piece, Wedge And Installed Position

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NOTE:

In this assembly overview pay attention, that the locking piece is in the correct installed position with the starter, if not the starter support bolts are difficult to install and the locking piece will no longer have its sealing capability.

Vehicles with a 3.0L TFSI Engine, or 3.0L TDI Engine

Fig 6: Engine to Transmission Bolts And Alignment Sleeves -A-

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A -Alignment sleeves

-- Attach the transmission to the engine and the tighten the bolts -1 and 6 through 11-.

Vehicles with a 4.0L TFSI Engine

Fig 7: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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A -Alignment sleeves

-- Attach the transmission to the engine and the tighten the bolts -1 and 6 through 11-.

Vehicles with a 6.3L FSI Engine

Fig 8: Identifying Transmission/Engine Bolts

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A - Alignment sleeves

-- Attach the transmission to the engine and the tighten the bolts -1 and 7 through 14-.

All Vehicles

-- Remove the Clutch Module Transportation Lock:T40170 .

-- Lift the transmission and tighten the bolts on the tunnel crossmember. Refer to ASSEMBLY MOUNTS OVERVIEW .

-- Loosen the tensioning strap and guide the Engine and Gearbox Jack:VAS6931 with the Gearbox Support:T40173 under the transmission.

-- Turn the crankshaft on the vibration damper 360° in the direction of engine rotation -arrow-.

Fig 9: Identifying Wrench - 21 MM T40263

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NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

-- Attach the torque converter to the drive plate as follows:

Fig 10: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14 to tighten the bolts -arrow-.

-- Install the first bolt -1- and tighten to 10 Nm, loosen and then tighten to 2 Nm (hand-tight).

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-- Turn the crankshaft on the vibration damper 180° in the direction of engine rotation, install bolt -4- and tighten to 60 Nm.

-- Turn the crankshaft another 60° the direction of engine rotation, install bolts -5 and 6- and tighten to 60 Nm.

-- Turn the crankshaft another 60° in the direction of engine rotation and tighten bolt -1- to 60 Nm.

-- Turn the crankshaft another 60° the direction of engine rotation, install bolts -2 and 3- and tighten to 60 Nm.

-- Tighten the remaining engine/transmission connecting bolts.

Install in reverse order of removal. Note the following:

-- Install the parking lock emergency release cable. Refer to FRONT EMERGENCY RELEASE CABLE, PARKING LOCK, REMOVING AND INSTALLING .

-- Attach the steering intermediate shaft to the steering gear. Refer to Steering Intermediate Shaft, Removing and Installing .

-- Install the drive axles and heat shield. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BC, 0BD, 0BE, 0BF] or DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BF & 0BE] .

-- Install the ATF pipes to the ATF cooler. Refer to OVERVIEW - ATF CIRCUIT .

-- Install the front muffler and align exhaust system free of tension. Refer to EXHAUST PIPES/MUFFLERS or EXHAUST PIPES/MUFFLERS .

-- Install the particulate filter and align the exhaust system free of tension. Refer to appropriate service information. .

-- Vehicles with 4.2L FSI and 6.3L FSI engines: install the left and right transmission mount. Refer to TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BC, 0BD, 0BE, 0BF] or DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BF & 0BE] .

-- Install the right coolant pipe on the transmission. Refer to [For engine(s) CPNA] Coolant Pipes, Removing and Installing [For engine(s) CPNA] Coolant Pipes, Removing and Installing .

-- Observe measures after connecting the battery. Refer to [For engine(s) CTUB, CEJA, CGTA, CDRA, CEUA, CPNA] Battery, Disconnecting and Connecting .

CAUTION:

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

Do not use a charger to jump start!

-- Check the parking lock emergency release. Refer to EMERGENCY RELEASE FROM P .

-- Check the ATF level and correct if necessary. Refer to ATF LEVEL, CHECKING .