Transmission, Removing
Transmission, removing
Special tools and workshop equipment required
^ 10 222 A Engine/transmission support bar
^ 3094 Hose clamp (3x)
^ 3004 Hooks (3x)
^ 3282 transmission support with 3282/48 pins (2x) and 3282/52 support
^ 3282/27 Adjustment plate
^ V.A.G 1383 A transmission jack
^ Chain (2x)
Removing
Notes: Any cable ties which were removed or cut through when the transmission was removed must be replaced by cable ties fitted in the same positions.
- Move gear shift to neutral position.
- Obtain radio code on vehicles with coded radio.
- With the ignition switched off disconnect the battery Ground strap.
- Remove covers -1- and -2- above lock carrier and battery - arrows -.
- Remove engine cover panel -1- above cylinder head cover (top arrows).
- Loosen hose clamp -4- and pull intake hose as well as connector -1- from mass air flow sensor.
- Remove hose -5- to secondary air pump at air filter housing.
- Then remove complete air filter housing by removing bolts -2- and - 3 -.
- Remove battery and battery carrier - arrows -.
- Remove bowden cable mounting bracket from transmission (arrows).
- Remove securing ring (arrow 1) from selector bowden cable reversing lever- A-.
- Remove nut (arrow 2) to remove shift bowden cable - B - with transmission shift lever.
- For this purpose use a puller, em. Kukko 20 10.
- Pull off selector bowden cable - A - reversing lever in direction of arrow.
- Then tie up shift bowden cable with transmission shift lever and selector bowden cable with reversing lever.
- Disconnect connector from speed sensor (arrow).
- Unbolt Ground cable -1 -.
- Unplug connector-3- from starter. Do not disconnect cable - 4 -.
- Unplug connector-2- and pull out of the retainer.
- Detach cables from retainer on starter and move clear to the side; unbolt retainer.
- Then remove upper securing bolt on starter.
Vehicles with 2 charge air coolers
- Slacken ribbed belt by turning tensioning element in direction indicated (arrow).
Notes: Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when refitted, this can result in breakage. When installing the belt, ensure it is correctly seated in the pulleys.
- Remove ribbed belt.
Vehicles with 1 charge air cooler
- Disconnect air duct at bottom of right - hand longitudinal member - arrows - (air duct leads to charge air cooler).
All models
- Take off both front wheels.
- Remove noise insulation in the center and on left and right sides - arrows -.
Vehicles with 2 charge air coolers
- Remove connecting pipe between the two charge air coolers - arrows -.
- Unbolt belt pulley for power steering pump; counterhold with Allen wrench.
All models
- Clamp off supply hose and pressure hose at vane pump using hose clamps 3094.
- Unplug connector -1- on power steering pressure switch.
- Unscrew pressure pipe -2- on power steering vane pump.
- Detach power steering pipe from transmission - arrows - and pull speed nut off transmission. Notes: If installed, detach additional pipe retainer.
- Take out lower bolt securing starter and detach starter.
- Clamp off pressure hose for clutch slave cylinder using hose clamp 3094.
- Pull retainer upward - arrow - and pull the pressure pipe -1- out of hose connector.
- Unplug connector from reverse light switch - 2 -.
- Slacken clamp - arrows - on exhaust system and disconnect exhaust pipe.
- Push clamp toward rear of vehicle.
- Loosen exhaust system in place by inserting hooks 3004 on ends of chain into floor pan openings (remove plugs if installed).
Notes: Do not bend the flexible joint (decoupling element) in the exhaust system more than 10°, otherwise it could be damaged.
- Mark position of driveshaft relative to flexible coupling on bevel box.
- Unbolt driveshaft from flexible coupling on bevel box (arrows).
Notes: Use a suitable lever to brace the triangular flange when loosening the bolts.
- Press the front driveshaft tube as far back as possible.
Notes: After loosening the bolts - A - (Fig. N34-0712 the engine/transmission assembly will move forward slightly. Make sure that the oil seal -arrow- on the driveshaft flange is not damaged when removing and installing.
- First remove bolts - A -, then remove bolts - B - on the pendulum support.
- Remove pendulum support.
- Press engine/transmission forward carefully.
- If fitted, unbolt front bracket for exhaust system - arrow - from subframe.
- Remove steering box bolts - 2 -.
- Lever steering box off subframe (dowel sleeve).
- Place transmission jack V.A.G 1383 A with universal support 1359/2 under subframe.
- Remove subframe bolts -1- and - 3 -.
- Lower subframe carefully, leaving it suspended from the suspension ball joints and connecting links. Lift the steering box clear at the same time.
- Secure steering box up out of the way.
- Disconnect drive axles from drive flanges, guide toward the rear, and place on the subframe. When doing this, take care not to damage surface protection.
- Tie up subframe toward rear of vehicle with a chain by inserting hook 3004 into floor pan opening (remove plug if fitted).
- Remove heat shield for right drive axle on bevel box.
- Unscrew bolts -1- and -2- on bracket for bevel box.
Notes: The bracket cannot be removed at this stage and should be Jeff in position.
Notes: The small cover plate -2- behind the bevel box is not visible when the bevel box is installed. Illustration shows transmission removed.
- Unscrew bolt (10 mm A/F) -1- and remove cover plate for flywheel behind bevel box.
- Fit support bar 10 222A together with legs 10 222 A/1.
- Set up support bar on wheel housing panels (arrows).
- Take up weight of engine/transmission assembly on the spindle.
- Unbolt left transmission support (bolts -1- and - 2 -).
- Lower engine/transmission assembly on the spindle ....
- ... until distance between transmission housing and transmission mount - a - = 100110 mm.
- Complete transmission jack with 3282 transmission support, 3282/27 adjustment plate for "O2M" transmission and mounting components as follows:
- Place 3282/27 adjustment plate onto 3282 transmission support (adjustment plate only fits in one position).
- Position transmission support arms according to holes in adjustment plate.
- Bolt in mounting components - A -, as displayed on adjustment plate.
- Place transmission jack under vehicle, arrow symbol - B - (Illustration A34 -0236) on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and secure support to transmission with bolt M8 x 25. arrow -.
- Unscrew engine/transmission securing bolts accessible from below.
- Press transmission off dowel sleeves.
- Remove bracket for bevel box.
- To separate transmission from engine, pull it away on the bevel box side first and then at the front.
- Then lower transmission carefully.