Transmission, Disassembling And Assembling: Installing

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-- Bring the gear actuator into the basic setting.

-- Push the gear actuator by hand and turn it at the same time until it engages and determine the current backlash.

Vehicles with self-locking center differential 

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-- Check if the needle bearing -arrow- is installed.

Continuation for all vehicles 

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-- Carefully insert the gear set.

-- Evenly combine the bearing area and the gear actuator.

Vehicles with self-locking center differential 

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-- Install the needle bearing -arrow-.

Continuation for all vehicles 

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-- Hand tighten the bolts -2- in the gear actuators -1-.

• When the gear positioner is installed correctly the dimension -X- is approximately 2 mm.

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-- Tighten the bolts for the gear positioner to the tightening specification.

-- Install the Transmission Input Speed Sensor 1 -G632- and tighten the bolt -A-.

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-- Install the wire in the bracket -B- at the same time pay attention to the correct routing.

-- Install the Gearbox Assembly Tool: T40213A  on the transmission.

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Tip:

• This step is necessity to that the bearing "E" in the transmission housing can be mounted correctly on the shaft.

-- Install the spindle from the Gearbox Assembly Tool: T40213A  by hand until the input shaft has raised approximately 2 to 3 mm and there is a small resistance when turning.

-- Position the new seal on the clutch housing and check if both centering pins are installed.

-- AWD vehicles: slide the Assembly Tool: T40367  -1- onto the transmission output shaft.

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• Ignore -item 2-.
• The Assembly Tool: T40367  acts as an assembly aid when assembling the transmission housing.

-- Warm the inner race of the bearing "E" -arrow- with the Hot Air Blower: V.A.G 1416  to a maximum of 100 °C (212 °F).

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-- Guide the transmission housing with the transmission.

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-- Install the new circlip -1- for the bearing "E".

• The circlips have different installed dimensions.
• If the bearing "E" is not replaced, a circlip with the same dimension as the old circlip must be installed.
• For a new bearing "E" the largest possible circlip to be installed must be used.

-- Remove the Gearbox Assembly Tool: T40213A  from the transmission.

-- Tighten the transmission housing with new bolts.

-- Tighten the bolts for the transmission housing to the tightening sequence. Refer to Figure.

-- Push in the centering bracket -A- for the gear set all the way.

Tip:

• Bolt -6- without centering sleeve.

-- Tighten the new bolts for the gear set -1 to 6- to the tightening sequence. Refer to Figure.

Vehicles without self-locking center differential 

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-- Install the oil catch tray -1-.

-- Press in the new end cover with the Press Tool: T40323  .

Vehicles with self-locking center differential 

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-- Install the oil catch tray -1-.

-- Installing the self-locking center differential. Refer to the appropriate Service Information .

Continuation for all vehicles 

-- Dual Clutch, Installing. Refer to DUAL CLUTCH, REMOVING AND INSTALLING .

-- Fill the ATF. Refer to ATF, DRAINING AND FILLING .

-- Fill the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- If equipped, install the all-wheel drive clutch. Refer to ALL-WHEEL DRIVE CLUTCH, REMOVING AND INSTALLING .

-- Dispose of the hydraulic pressure reservoir. Refer to HYDRAULIC PRESSURE RESERVOIR, DISPOSING .