Transmission, Disassembling and Assembling
Transmission, disassembling and assembling
End cover, removing and installing
Special tools and workshop equipment required
^ Engine support bracket 10-222 A
^ Removal lever 80-200
^ Multi-point bit 3357
^ Engine/transmission jack V.A.G 1383 A
^ Waste fluid container
CAUTION!: Do not run engine or tow vehicle with end cover removed or when there is no ATF in the transmission.
Note:
^ Observe the rules for cleanliness when working on the automatic transmission
^ Refer to General repair instructions
Removing
^ Remove engine cover panel.
^ Set up support bar 10-222 A on fender panel flanges. Spindle goes toward rear of vehicle.
^ Connect hook on spindle with lifting eye on back of engine.
^ Take up weight of engine on spindle of support bar, but do not lift.
Note: Illustration shows vehicle with 4-cyl. engine.
- Drain ATF.
Vehicles with 4-cylinder engine
- Remove cover plates on underside of vehicle inner left -2- and inner right -1-.
- Remove rear crossmember on underside of vehicle -1 ... 4-.
All models
- Remove front crossmember on underside of vehicle -1 6-.
Note: Illustration shows vehicle with 4-cyl. engine.
Vehicles with 6-cylinder engine
- Remove one of two front exhaust pipes.
All models
- Loosen clamp (arrows) on exhaust system and disconnect exhaust pipe.
Note:
^ The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10°- otherwise it can be damaged.
^ illustration shows vehicle with 4-cyl. engine.
- Remove heat shield below shift mechanism.
- Remove universal support plate VAG 1359/2 from engine and transmission jack VAG 1383 A and place a square block of wood -1onto piston arm.
- Support tunnel crossmember using engine/transmission jack VAG 1383 A.
- First remove bolts -1- and -2-, then bolts -3- and -4-.
- Slowly lower tunnel crossmember using engine/transmission jack VAG 1383 A.
- Remove nuts (arrows) and disconnect tunnel crossmember.
- Release connector -A- in direction of arrow and disconnect from transmission.
- Move wiring harness clear.
- Unscrew bolts -2- and remove mounting base -3- for selector lever cable.
- Use removal lever 80-200 to pry selector lever cable -A- from selector shaft lever (arrow).
- Remove transmission support from transmission (arrows).
- Loosen bolts (arrows) and take off end cover.
Note: Use new bolts when installing.
Installing
Install in reverse sequence; note the following points:
Note: Replace gaskets and seals.
- Slide new twin-lip oil seal -A- onto connector of Transmission Control Module (TCM) -J217- with twin lips facing outward.
- Clean sealing surfaces of transmission housing and end cover.
- Install a new paper gasket -A- for end cover.
- Install end cover and take care that paper gasket does not slip.
- Install new bolts (arrows): tighten in crosswise pattern and hand-tight to start with and then tighten to specified torque.
Note: Use new bolts when installing.
- Carefully check installation position of twin-lip oil seal -A-: It must be flush (twin lips must not fold over).
- Check whether selector lever is in position "P" and carefully press socket end of selector lever cable -5- onto selector shaft lever -7-.
Note: Take care not to bend selector shaft lever when pressing it on, support it if necessary as otherwise selector mechanism can no longer be adjusted properly.
^ Insert bolts -2- into mounting base -3- for selector lever cable and tighten to 23 Nm in transmission.
^ Bolt transmission support onto transmission (arrows).
^ Install tunnel crossmember.
^ Check selector lever cable setting.
- Install exhaust system and align it to be free of stress
- Fill up with fresh ATF from.
Tightening torques