Transmission, Removing and Installing
WARNING!
^ Do not re-use any fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and coffer pins. Always follow the recommendations these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
Special Tools
The following special tools and test equipment are necessary for this work:
10-222 A - Engine support
10-222 A/2 - Extra hook
10-222 A/4 - Adapter for engine support
3180- Hanging device
VAG 1383 A - Lift
3282 - Transmission holder
3282/25 - Adjusting plate
Removing
CAUTION!
^ Before disconnecting the battery Ground (G.ND) strap, determine the correct coding for the anti-theft radio.
^ Bolts that are connected to the body must be stored separately (danger of contact corrosion from uncoated bolts).
^ No more than two mounting bolts for the subframe may be loosened at the same time. Otherwise, an axle alignment will be required.
^ Disconnect battery Ground (GND) strap.
^ Remove engine cover.
^ Remove intake air duct between air cleaner housing and throttle body.
^ Remove intake hoses between air cleaner housing and upper radiator support.
^ Loosen mounting bolts (arrows) on fan shroud and electric fan (electric fan can be laid to side while still connected).
^ Disconnect connectors for heated oxygen sensors, to right and left of throttle body .
^ Remove upper mounting nuts from front exhaust pipes on right and left sides.
^ Remove all engine/transmission connecting bolts that can be reached from above.
^ Remove covers over strut mounting and air cleaner housing.
^ Place holding device 10-222A with adapter for holding device 1 0-222A/4 (arrow -D-) on bolts of strut mount.
Notes:
^ The threaded spindle -B- must face forward and the threaded spindle -C- must face rearward.
^ Supports 10-222 Al1 must not be used.
^ Disconnect fuel line from pressure regulator (arrow).
^ Install holding device 3180 in holding eyes, from transmission side, and tighten.
^ Install additional hooks -A- (10222A/2) in holding eyes near pressure regulator.
^ Take up weight of engine slightly using spindles -B- and -C-.
When lifting or lowering the engine:
^ Make sure neither hooks -B- nor additional hooks -A- contact pressure regulator (arrow).
^ Remove front wheels.
^ Remove noise insulation.
^ Unclip air duct for generator.
^ Remove heat shields for right and left drive axles (arrows).
^ Remove right and left drive axles from transmission flanges.
^ Remove heat shield on left under multi-function switch.
^ Remove lower mounting nuts for front exhaust pipes on exhaust manifold.
^ Remove heated oxygen sensors behind three way catalytic converters.
^ Loosen double clamp and remove front pipes together with heated oxygen sensors and three way catalytic converters.
^ Remove heat shield -A- for drive shaft (arrows).
^ Disconnect drive shaft from transmission and tie up.
^ Remove lower mounting bolts (arrows) from engine mounts.
^ Remove mounting bolts (arrows) for right-front torque arm.
^ Using spindles, raise engine until engine mount comes out of subframe.
CAUTION!
Make sure that the throttle body does not damage the insulation liner on the bulkhead.
^ Remove lower mounting bolts between engine oil pan and transmission.
^ Remove right engine support and cable clamps (arrows).
^ Place engine mount on subframe.
The starter is removed as follows:
^ Remove remaining mounting bolts from starter and bracket (arrows).
^ Turn starter outward slightly.
^ Disconnect wiring connections from starter as follows:
- Remove positive cable -1-.
- Disconnect wire -2-.
^ Pull starter outward.
^ Remove 3 bolts for torque converter through opening for starter (turn crankshaft 1/3 revolution further for each bolt).
Note:
To loosen the bolts for the torque converter, counter-hold the center bolt on the vibration damper.
^ Lower engine and install left engine mount on subframe, tightening lower mounting bolts slightly.
^ Remove rear bracket for noise insulation -1-.
^ Move safety lever -4- and disconnect connector for transmission wiring harness.
^ Disconnect connector for multifunction switch -2- and disconnect bracket for connector -3-.
^ Disconnect speedometer Vehicle Speed Sensor (VSS) -G22-.
^ Remove Engine Speed (RPM) sensor -G23- from left front of transmission.
^ Remove multi-function switch.
^ Press ball socket of selector lever cable -1- from transmission selector lever -2-.
^ If necessary, mark position of mounting bracket for selector lever cable relative to transmission housing for reinstallation.
^ Disconnect holding clamp for ATF lines from left engine mount.
^ Place oil pan underneath transmission.
^ Disconnect ATF lines from transmission, pull out and lay to side.
^ Set up transmission holder 3282 with adjusting plate 3282/25 for removing the automatic transmission 01L and place on lifter VAG 1383A.
^ Support transmission from below using lifter VAG 1383 A and transmission bracket 3282.
Left support (arrow) must be attached securely with an M10 bolt.
Notes:
^ The symbols on the adjusting plate show the required brackets for the automatic transmission 01L. The arrow points in the driving direction.
^ The transmission can also be supported with the VAG 1383 A lift and the plate 135912.
^ Remove left transmission support complete with transmission mount.
Note:
The transmission support is not separated from the transmission mount.
^ Remove right transmission support complete with transmission mount.
Note:
The transmission support is not separated from the transmission mount.
^ Remove bolts -1- and -2-.
CAUTION!
The two mounting bolts for file front subframe must not be loosened. Otherwise an axle alignment will be necessary.
^ Lower rear subframe (maximum 100 mm or 3.94 inch) from mounting point on body by releasing tension on engine support.
^ Lower rear of transmission a small distance.
^ Support engine at front with commercial support.
^ Remove remaining engine/transmission connecting bolts.
^ Press torque converter off flex plate of engine using pry bar.
^ Press transmission off engine.
^ Lower rear edge of transmission by adjusting bracket 3282.
^ Disconnect connector for sender for transmission RPM (right-rear) and disconnect cable from transmission.
^ Guide transmission out diagonally (downward, to rear).
^ Subframe is lowered approximately 100 (3.94 inch).
Notes:
^ If necessary, decrease preliminary tension on the spindle of the engine support 10-222A.
^ Make sure there is enough clearance between the bulkhead and the engine.
^ Secure the torque converter so it will not fall out.
Installing
Note:
Before installing a replacement transmission, clean the oil cooler and oil lines.
Before installing the transmission:
^ Make sure torque converter is correctly installed in transmission.
^ Make sure dowel sleeves are correctly seated on engine housing.
The transmission is installed in reverse order of removal. Pay particular attention to the following:
^ Make sure that no hoses get pinched when engine and transmission are pushed together.
^ Use only original bolts to fasten torque converter to flex plate (M10 x 1 x 17). Always replace these bolts.
^ If necessary, slide shim plate between front longmember and torque arm.
^ Always replace self-locking fasteners.
^ Always replace gaskets and O-rings.
^ Always replace M14 bolts (and respective conical spring washers) for subframe.
^ Install subframe using appropriate tightening sequence.
^ Adjust selector lever cable.
^ Install exhaust system.
^ Check fluid level in final drive of automatic transmission.
^ Install drive axles.
^ Check ATF level.