Removal and Replacement

Transmission, removing and installing - 6 Spd. Manual Transmission 01E

Removing

Special tools, testers and auxiliary items required:





^ Engine-/Transmission lifter V.A.G 1383 A





^ Transmission support 3282





^ 3282/12 Adjustment plate
^ VAG1306 Drip tray

- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground strap.





- Loosen bolts (arrows) and remove engine cover panels (arrows -A- through -C-).





- Detach air intake duct. To do this, pull off retainer catch -1-, loosen clamps -2- and unscrew bolts -3-.
- Remove coolant system expansion reservoir and lay to one side.





- Unplug connector for oxygen sensor on left (arrow -2-) and move wire for oxygen sensor clear.





- Unplug connector for oxygen sensor on right -1- and move wire for oxygen sensor clear.





- Unscrew two bolts securing heat shield -2- on exhaust pipe (right and left).
- Unscrew nuts -3- on exhaust pipe (right and left).
- Unscrew engine/transmission securing bolts accessible from above.





- Remove noise insulation (arrows).





- Unbolt bracket for noise insulation (arrow).
- Unbolt heat shields from transmission above left and right drive axles (arrows).
- Unbolt left and right drive axles -1- from transmission, lift clear and tie in position.

Note:
Take care not to damage protective coating on drive axles.

- Loosen exhaust system clamps and push clamps towards rear.





- Remove heat shield for driveshaft from cover for Torsen differential (arrows).





- Unbolt driveshaft -1- from transmission and rest it on heat shield -2-.
- Secure driveshaft to fuel pipe bracket -3- with wire (arrow).





- Remove bolts (arrows) and remove transverse mount -A-.
- Completely remove brackets -B- at right and left exhaust pipe. To do this, bolts -2- and -3- must be removed.





- Unscrew and remove bolts -1- and -2- on right and left and remove support -A-.





- Lower subframe at rear and place spacer (e.g. wedge of wood) in gap.

^ -a- = max. 50 mm





- Unscrew bolts -1- and -2- and remove right and left transmission supports from transmission and subframe together with bonded rubber mountings.





- Loosen clamp -3-, lift heat shield -2- slightly and unscrew remaining nuts -5-.
- Lift heat shield -2- and pull out front exhaust pipe together with catalytic converter -4-.
- Note that oxygen sensor -1 - and oxygen sensor wire have to be guided through opening in heat shield -2-.

Note:
Avoid excessive bending of the flexible pipe connection (decoupling element) on the front exhaust pipe. The angle between the catalytic converter and the front exhaust pipe must not exceed 10°, otherwise the flexible connection will be damaged.





- Lift the transmission for access to the two lower bolts securing engine to transmission.

A - Axle stand
B - V.A.G 1383 A





- Unscrew two bolts securing transmission to engine (arrows).

Note:
The two hex socket head bolts M 10 x 60 must be replaced by new hex bolts M 10 x 55 (Part No. N 104 684 01) so that the two bolts (arrows) can be tightened with a torque wrench after installing the transmission.

- Lower transmission again slowly.





- Remove engine speed sender -G28 from left-hand side of transmission (arrow) and place to one side.
- Pull connector off sender for speedometer.
- Pull off connector on reversing light switch.
- Unbolt the starter and push it as far as it will go towards the front.

Note:
Do not disconnect cables at starter.





- Unbolt connecting rod -2- for selector rod on right-hand side of transmission.
- Remove hex socket head bolt from push rod -1-.





- Unscrew nut -1- and pull selector rod lever -2- off transmission selector shaft.





- Set up transmission support 3282 with adjustment plate 3282/12 for removal of manual transmission 01E (all-wheel drive) and place on transmission jack V.A.G 1383 A.

A - Attachments

Notes:





^ The positions for the attachments are indicated by symbols (-A-). Arrow -B- points in the direction of travel.
^ Adjustment plate 3282/12 can only be installed in one position.

- Remove all but one of the engine/transmission securing bolts from below (one bolt is left in place to hold engine and transmission together).





- Run transmission jack V.A.G 1383 A with transmission support 3282 in under transmission and take up weight of transmission.
- Secure transmission to transmission support 3282.

Note:
If transmission support 3282 is not available, the transmission can be removed and installed using transmission jack V.A.G 1383 A.

- Remove last remaining engine/transmission securing bolt.
- Press transmission off dowel sleeves and lower carefully with transmission jack V.A.G 1383 A just far enough for access to slave cylinder.

Note:
When lowering transmission ensure hydraulic line/hose to slave cylinder is not damaged.





- Remove bolt (arrow) and take out slave cylinder from the rear. Do not open line/hose system.

Note:
Do not depress clutch pedal after removing slave cylinder.

- Lower transmission completely.

Note:
When lowering transmission ensure there is sufficient clearance to drive axles.

Installing

Installation is carried out in the reverse order, when doing this note the following:

- Always replace all seals and gaskets.
- Always replace all self-locking nuts.
- Check whether dowel sleeves for aligning transmission with engine are in engine flange. Insert if necessary.
- Clean input shaft splines and (in the case of used clutch plates) hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to splines. Do not grease guide sleeve.
- Check clutch release bearing for wear and replace if necessary.





- Coat area -a- of collar with lithium grease G 052 150 A2 before mounting slave cylinder into transmission housing.
- Coat contact surface for clutch slave cylinder push rod with a thin layer of copper grease, e.g. Z381 351 TE.
- On vehicle with V6 bi-turbo engine, fit intermediate plate on dowel sleeves on engine flange.





- Two hex socket head bolts M 10 x 60 must be replaced by new hex bolts M 10 x 55 (Part No. N 104 684 01) so that two bolts (arrows) can be tightened with a torque wrench after installing transmission.
- Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between engine and transmission.





- Lift transmission until clutch slave cylinder with bracket for line/hose can be installed (arrow).
- Align exhaust system free of stress.
- Before installing, use a tap to clean threads in drive flange for driveshaft on transmission to remove traces of locking compound.
- Replace gaskets on drive axles and on front of driveshaft.
- Bolt on driveshaft.
- Check adjustment of selector rod and push rod; readjust if necessary.
- Check oil level in transmission.
- After connecting battery, enter anti-theft code for radio
- Close windows fully using electric window switches.
- Operate all electric window switches again for at least one second in "close" direction to activate automatic one-touch function.
- Set clock to correct time.





Vehicles with 6-cyl. bi-turbo engine





Dowel sleeves -A- for aligning.

1) The two hex socket head bolts M 10 x 60 must be replaced by new hex bolts M 10 x 55 (Part No. N 104 684 01) so that the two bolts -4- can be tightened with a torque wrench after installing the transmission.





1) Always replace bolts





Subframe to body





1) Always replace bolts washers





For 6-cylinder bi-turbo engine only

Cross-piece -A- to subframe 1) 40 Nm + 90 degrees

1) Install bolts -1- from the bottom. Always replace nuts and bolts.