Transmission, Removing
Transmission, removing (vehicles with 4.2 ltr. MPI engine), 09L, 6 Spd. A/T AWD
Special tools, testers and auxiliary items required (part 1):
Special tools, testers and auxiliary items required (part 2):
^ Engine support bridge 10-222 A
^ Shackle 10-222 A/12
^ Hose clamps, up to 25 mm dia. 3094
^ Transmission support 3282
^ Adapter 3282/48
^ Engine/transmission jack V.A.G 1383 A
^ Bracket 30-211 A
^ Pin 3282/50
^ Insert pad for front fender T40045
^ Adapter T40058
^ Bolt M10x20
Removing
Note:
^ General repair instructions go to General repair instructions.
^ Read the rules for cleanliness when working on the automatic transmission.
^ All cable ties which are released or cut open during removal must be installed in the same position when installing.
^ Heat insulation sleeves removed during removal of transmission must be installed in the same position when installing.
- Shift selector lever to position "P".
CAUTION: Follow steps required when disconnecting battery.
- Slide battery cover toward right side of vehicle - arrow 1 - and remove - arrow 2 -.
- With ignition switched off, disconnect Ground (GND) wire - arrow - at battery.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
- Remove cover - 1 - on left side of engine compartment.
- Disconnect coolant hose - 2 - with hose clamp 3094 and detach at coolant expansion tank.
- Unbolt coolant expansion tank - arrow -.
- Disconnect electrical wire leading to Engine Coolant Level (ECL) warning switch F66 at expansion tank (bottom) and move coolant expansion tank (with coolant hose - 1 - attached) clear to one side.
- If necessary, close off connection with a suitable plug.
- Disconnect electrical connectors - 1 to 4 - from retainer at left of bulkhead.
- Disconnect electrical connectors - 1 -, - 3 - and - 4
- Detach retainer at bulkhead.
- Detach heat insulation sleeve at wiring harness and move wiring harness clear.
- Move Lambda probe wires clear (downward).
- Remove cover - 1 - on right side of engine compartment.
- Remove air intake hose - arrows -.
- Disconnect connectors - 1 to 4 - from retainer at right of bulkhead.
- Disconnect electrical connectors - 2 - and - 4
- Move Lambda probe wires clear (downward).
Note:
^ Mark the attachment points for the Lambda probe wires, to make sure they are attached in the same place during installation.
- Install shackle 10-222 A/12 to engine lifting eye (right rear).
Note:
^ - Item 1 - can be disregarded.
- Detach rubber seal from edges of fender mounting flanges.
- To avoid damaging edges of fender panels with engine support bridge 10-222 A, insert insert pad for front fender T40045 on both sides between the fender mounting flange and body panel underneath.
- Place engine support bridge 10-222 A with adapters 10-222 A/3 onto fender panel flange, as shown in illustration.
- Engage spindles of engine support bridge 10-222 A in engine lifting eye (front) and in shackle 10-222 A/21 (rear).
- Take up weight of engine on spindles of support bar, but do not lift.
- Remove both front wheels.
- On vehicles equipped with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary heater to sound insulation.
- Release quick release fasteners - 1 -, remove bolts - 2 - and remove sound insulation.
- Remove bracket for sound insulation - arrows -.
- Remove bracket for wiring harness at engine support (right-side) - arrows -.
- If installed, unclip operating rod for vehicle level sensor from lower transverse link - arrow - or detach connector at operating rod (top).
- Remove bolt - 2 - (on left and right).
Note:
^ Ignore - item 1 - and - items 3 to 5 -.
- Remove nuts (left and right) - 1 to 4 - for stabilizer bar mounting and remove stabilizer bar.
- Remove securing bolts (left and right) - 3 - for transmission mounting - B - at subframe - C -.
- Before loosening subframe, use locating pin 3393 to check whether holes - 1 - and - 2 - are aligned.
If this is not the case, wheel alignment has to be performed after installing subframe.
- Remove bolts - 1 to 4 - and lower subframe.
Note:
^ The subframe may be allowed to rest on the transverse links. It does not have to be removed completely.
Note:
^ To prevent damage, the flexible couplings in the front exhaust pipes must not be bent further than 10°.
- Disconnect exhaust system at clamps - arrows -.
- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Slide driveshaft together toward rear final drive. The constant velocity joints can be moved axially.
- Tie driveshaft to side, onto heat shield - arrow -.
- Disconnect 16-pin electrical connector - 2 - at transmission by folding out the release tab and turning fastener cap counter-clockwise.
Note:
^ - Item 1 - can be disregarded.
- Remove heat shields - arrow - for drive axles (left and right).
- Remove drive axles (left and right) from flange on transmission.
Note:
^ Make sure you do not damage surface coating on drive axles.
- Remove bracket (right-side) - arrow - for refrigerant line.
- Disconnect electrical connector - 1 -.
- Remove bolts - arrows - and remove engine support together with engine mounting.
- Remove Ground (GND) wire - 5 - Disconnect wires - 3 - and - 4 -.
- Remove nut - 1 - and bolt - 2 -.
- Remove starter.
- Insert guide pin of adapter T40058 so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 faces adapter.
- Counter-hold crankshaft using adapter T40058 to loosen torque converter bolts.
- Remove 3 bolts from torque converter through opening for starter (turn crankshaft 1/3 of a turn to access one bolt after another).
- Remove lower engine/transmission securing bolts - arrows -.
- Mark position of mounting bracket for selector lever cable relative to transmission housing to simplify reassembly. Unbolt mounting bracket - arrows -.
- Loosen clips securing ATF lines to transmission and engine go to ATF cooling lines.
- Lower engine/transmission assembly as far as possible, using spindles of support bracket.
CAUTION: When lowering the engine/transmission assembly, make sure none of the lines or wires are stretched or pinched and also avoid causing damage to any other components.
Note:
^ Mark the attachment points for the Lambda probe wires, to make sure they are attached in the same place during installation.
- Remove bolt - arrow - at bracket for front exhaust pipe (left-side).
- Remove nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
Note:
^ In the illustration the engine has been removed.
- Detach front exhaust pipe from exhaust manifold (left-side).
- Remove front exhaust pipe.
- Remove bolt - 2 -.
- Remove heat shield - B -
- Remove bolt - 1 -.
- Pull engine speed (RPM) sensor G28 - item A - out of transmission.
Note:
^ The engine speed (RPM) sensor G28 is inserted in bell housing (top left).
- Remove bolt - arrow - at bracket for front exhaust pipe (right-side).
- Remove nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.
Note:
^ In the illustration the engine has been removed.
- Remove front exhaust pipe.
- Remove bolts - 2 - at transmission supports (right and left) and detach heat shields - B -.
- Remove bolts - 1 -.
- Detach transmission support - A - together with transmission mounting from transmission.
- Use removal lever 80-200 to pry ball socket - 1 - on selector lever cable off selector shaft lever.
Note:
^ Do not bend or kink the selector lever cable.
^ - Item 2 - can be disregarded.
- Set up transmission support 3282 on engine/transmission jack V.A.G 1383 A.
- Place Adapter 3282/48 on transmission support 3282 as shown in illustration.
- Align arms of transmission support according to holes in adjustment plate.
- Attach support elements as illustrated on adjustment plate.
- Note: The pin 3282/50 has to be screwed in at rear right.
Note:
^ The pin 3282/50 is flattened at the side - arrow -, the flattened side should face the oil pan when inserting pin into transmission.
- Place engine/transmission jack V.A.G 1383 A with transmission support 3282 underneath transmission.
Note:
^ The arrow symbol on the adjustment plate points in the direction of travel.
- Align adjustment plate parallel with transmission.
- Bolt support to left rear tapped hole on transmission - 1 - using one bolt M10x20.
- Insert flattened pin 3282/50 into mounting hole at right rear of transmission housing - arrow 2 -.
CAUTION:
^ The flattened side of the pin must face toward the transmission oil pan to prevent the oil pan from being bent or damaged.
^ Replace the transmission oil pan if damaged.
- Insert pin into mounting hole at left front of transmission housing - arrow 2 -.
- Insert pin into recess in housing at right front of differential housing - arrow 1 -.
- Place drip tray in position.
- Remove bolts - 2 -.
- Pull ATF cooling lines off transmission.
- Seal lines and transmission connections with clean sealing plugs to prevent ATF from escaping.
- Remove all remaining securing bolts between engine and transmission.
- If necessary, lower engine slightly again via spindles.
- Use assembly lever to press torque converter off drive plate of engine - arrow -.
- Press transmission off engine.
- Lower rear edge of transmission by adjusting transmission support 3282 accordingly.
- Guide transmission out diagonally downward/to rear.
Note:
^ When lowering transmission, make sure there is sufficient clearance to drive axles.
- Secure torque converter in transmission using Bracket 30-211 A to prevent it from dropping out.