Transmission, Installing
Transmission, Installing
Installation of transmission is the reverse of removal. The following points must also be observed:
Before installing:
- Clean threads in output flange/driveshaft flange using a tap.
- Clean ATF lines. Refer to => [ ATF Lines and Cooler, Cleaning ] 01VA Transmission.
- Insert torque converter correctly into transmission
CAUTION!
In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is flanged to the engine.
Installation dimension for torque converter, checking
When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approx. 23 mm.
If the torque converter is not inserted completely, this distance will be approx. 11 mm.
- Make sure bushings are correctly seated.
• If the bushings get stuck in the transmission housing, they must be removed and new bushings must be installed on the engine.
For 4 cylinder engines:
Item A = bushings
For 6 cylinder engines:
Item A = bushings
- Prepare transmission support (3282) for Automatic Transmission 01V with adjustment plate (3282/10 ) and place it on the engine/transmission hoist ( VAG1383A).
• The symbols on the adjustment plate indicate the necessary mounts for Automatic Transmission 01V and the arrow points toward front of vehicle.
- Place transmission onto transmission support.
- Secure transmission on transmission support ( 3282) using bolt - A -.
- Move transmission into position between the lowered subframe and vehicle floor.
- Align transmission properly to engine.
- Tighten one engine/transmission connecting bolt at either side by hand.
- Make sure that wires do not get pinched as transmission is docked at engine.
CAUTION!
Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.
- Bolt together torque converter and drive plate.
- To do this insert bolts by hand and tighten to tightening torque.
- Insert top engine/transmission connecting bolts and tighten to tightening torque.
• Some bolts also have a bracket or a Ground (GND) connection attached. Refer to => [ Tightening Specifications ] Tightening Specifications - Controls, Housing.
- Raise engine-transmission-subframe using the spindles approx. 4 turns. To do this use Support (VAS5058).
- To do this raise engine/gearbox assembly using spindles in turn, 2 turns at a time.
- At the same time raise engine-transmission-subframe using lifter (VAG1383A) (second mechanic).
- Insert remaining engine/transmission connecting bolts and tighten to tightening torque
- Install subframe, observe tightening sequence and alignment with master bore hole.
- Only perform vehicle alignment if necessary.
- Install right transmission support with transmission mount => [ Transmission Mounts ] 01VA Transmission
- Install lower nuts - A - on left and right engine mounts.
Vehicles with six-cylinder engine:
- Bolt on torque support stop - 1 - - arrows -. Refer to => Engine Mechanical Engine
All:
- Attach retaining clip for coupling rods of Left Front Level Control System Sensor (G78) to left front control arm, if present.
- After subframe is installed, remove bolt - A - and remove transmission jack (VAG1383A).
- Apply corrosion protection to contact surface between bolt - A - and oil pan.
- Push lever/selector shaft - 2 - on transmission fully forward (on illustration fully left).
- Shift selector lever into "S" and carefully press up ball head of selector lever cable - 1 - on lever/shift rod - 2 - using a pair of pliers.
• Do not deform lever/shift rod when pressing up or else shifting cannot be precisely adjusted any more.
- Bolt on mounting bracket for selector lever cable to transmission corresponding to marking for re-installation of transmission.
- Install shielding plate/selector lever cable, if present.
- Install Multi-Function Transmission Range (TR) Switch (F125). Refer to => [ Multi-Function Transmission Range Switch ] Multi-Function Transmission Range Switch.
- Install left transmission support with transmission mount. Refer to => [ Transmission Mounts ] 01VA Transmission.
- Bolt driveshaft to transmission.
- Install heat shield for driveshaft at transmission - arrows -.
- Install starter.
- Connect ATF lines - 1 - according to the respective color markings.
- Engage clamp for ATF lines and tighten nut - 2 -.
- Connect connector of Speedometer Vehicle Speed Sensor - arrow A -.
- Bolt Engine Speed (RPM) Sensor (G28) - arrow B - to transmission.
- Install noise insulation bracket - 1 -.
- Connect connector - 2 - of wire for multi-function switch.
- Connect connector for transmission wiring harness and swivel securing lever- 3 -.
- Replace cable ties - 4 -.
- Bolt on left and right drive axles - 1 - to transmission flanges.
- Install heat shields for left, if present, and right drive axles - arrows -.
Third bolt is not visible in the illustration.
- Install front exhaust system with catalytic converter.
- Install noise insulation panel - arrows -.
- Install front wheels.
- Remove engine support bridge (10-222A).
- Fit intake air duct to intake manifold.
- Install intake air guides.
- Install engine cover.
- Install left and right covers in engine compartment.
See Caution for connecting Telematics battery. Refer to => [ Transmission ] Transmission
- After connecting battery, enter anti-theft code for radio.
- Check adjustment of selector lever cable. Refer to => [ Selector Lever Cable, Checking and Adjusting ] 01VA Transmission.
- Check gear oil in front final drive with transmission installed. Refer to => [ Front Final Drive Gear Oil, Checking ] [1][2]Front Final Drive Gear Oil, Checking.
- Then check ATF level and top off. Refer to => [ ATF Level, Checking ] [1][2]ATF Level, Checking.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.