Transmission, Installing

Special Tools And Workshop Equipment Required

Torque Wrench 1332 Insert - Ring Wrench - 16 mm VAG 1332/14
Counterhold - Vibration Damper T10355 for vehicles with 4-cylinder TFSI engine 2.0L engine
Clutch Module Assembly Aid T40169
Clutch Module Transportation Lock T40170

Procedure

NOTE:

Replace any 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 .

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

-- Before installing a replacement transmission, always clean out the ATF cooler and ATF pipe/hose line 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, transmission mount and tunnel crossmember in the new transmission; refer to OVERVIEW - SUBFRAME MOUNT .

Fig 1: Attaching Exhaust System Retaining Strap Bracket To New Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Attach the exhaust system retaining strap bracket -1- to the new transmission, refer to OVERVIEW - MUFFLER .

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

Fig 2: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

Courtesy of AUDI OF AMERICA, LLC

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

Fig 3: Insert Assembly Aid T40169 into transmission housing

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-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing and the dual mass flywheel from below as shown in the illustration.

The Clutch Module Assembly Aid T40169 must engage in the semi-circular opening -1- and into the check hole -2-.

NOTE:

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

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

Fig 4: Identifying Transportation Lock T40170

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

Fig 5: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

-- 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 TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Position the transmission on the engine and tighten the engine/transmission connecting bolts.

-- Remove the Clutch Module Transportation Lock T40170 and the Clutch Module Assembly Aid T40169.

-- Tighten the bolts for the tunnel crossmember, refer to OVERVIEW - SUBFRAME MOUNT .

-- Loosen the tensioning strap and guide the Engine and Gearbox Jack VAS 6931 with the Gearbox Support T40173 under the transmission.

NOTE:

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

Fig 6: Pressing Torque Converter

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

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

Fig 7: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

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

Vehicles with 4 cylinder TFSI 2.0L engine:

Fig 8: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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-- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the Counterhold - Vibration Damper T10355.

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

Fig 9: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

-- Continue turning the crankshaft 120° and tighten the remaining two bolts to 60 Nm.

Vehicles with 4-cylinder TDI 2.0L engine:

Fig 10: Identifying Offset Open-End Wrench

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-- Turn the crankshaft 240° further in the direction of the engine rotation -arrow- on the central bolt on the vibration damper with an angled wrench -1-.

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

Fig 11: Identifying Clutch Module First Bolt Installation Location

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-- Continue turning the crankshaft 120° and tighten the remaining two bolts to 60 Nm.

Vehicles with 6-cylinder engine:

Fig 12: Identifying Guide Pin And Adapter T40058

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-- Insert the adapter 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 Crankshaft Socket T40058 -arrow-.

Fig 13: Identifying TDC With Special Tool Adapter T40058

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

Fig 14: Identifying Clutch Module First Bolt Installation Location

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-- Continue turning the crankshaft 60° and tighten the remaining 5 bolts to 60 Nm.

All vehicles:

Install in reverse order of removal. Note the following:

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

Fig 15: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

-- Connections and routing, refer to appropriate SYSTEM WIRING DIAGRAMS information.

-- Install the ATF lines and the ATF cooler, refer to OVERVIEW - ATF CIRCUIT .

-- Install the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Attach the steering intermediate shaft to the steering gear, refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install selector lever cable, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Installing the driveaxle and driveaxle heat shield, refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the plenum chamber bulkhead, refer to OVERVIEW - PLENUM CHAMBER BULKHEAD .

-- Install the exhaust system, refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Install the subframe heat shield, refer to OVERVIEW - HEAT SHIELDS .

-- Install the driveaxle covers and noise insulation, refer to FRONT NOISE INSULATION, REMOVING AND INSTALLING .

-- Install the front wheels, refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Observe measures after connecting the battery, refer to BATTERY -A-, 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 and adjust the selector lever cable, refer to SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Fill the engine coolant, refer to COOLANT, DRAINING AND FILLING .

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

-- After repairing the transmission, check the axle oil level in the front final drive and adjust if necessary, refer to GEAR OIL, CHECKING LEVEL .