Removing
Removing
Special tools, testers and auxiliary items required
^ Support bracket 10 - 222 A
^ Bracket 10 - 222 A /1
^ Engine/transmission jack V.A.G1383 A
^ Transmission support 3282
^ Shackle 10 - 222 A /12
^ Hose clamps, up to 25 mm diameter 3094
Special tools, testers and auxiliary items required
^ Adjustment plate 3282/42
^ Hooks 3004
Note:
^ Read rules for cleanliness when working on the transmission
^ General repair instructions.
^ Observe notes on direct shift transmission 02E
Removing
Note: All cable ties which are released or cut open when removing the transmission must be reinstalled in the same position when installing the transmission.
- Remove cover panel (front left) - arrows -
Caution: The following steps are required when disconnecting the battery
Note: The battery is located in the rear compartment, in the spare wheel well.
- Disconnect ground strap on battery (in rear compartment) with ignition switched off.
- Loosen clamp - 4 - and disconnect intake hose and connector - 1 -from mass air flow sensor.
- If installed, disconnect hose - 5 - from air cleaner housing.
- Remove bolts - 2 - and - 3 - and remove complete air cleaner housing.
- Unclip complete main fuse box/battery - A - including all wiring from battery tray.
- Remove battery tray - arrows -
Note:
^ The sole purpose of the battery tray is to secure the main fuse box/battery.
^ The battery is located in the rear compartment, in the spare wheel well.
- Shift selector lever into "P" position.
- Push circlip - A - upward and remove it in direction of arrow.
- Press selector lever cable off selector shaft lever in direction of arrow and place on top.
- Do not loosen bolt - B - .
- Remove two bolts - 1 -
Note: Do not kink selector lever cable.
- Touch vehicle ground with your hand (without gloves) to discharge any static electricity.
- Turn bayonet catch - 1 - of 20-pin connector to release and disconnect it from transmission.
Caution: Never touch contacts in the transmission connector with your hands, as static discharge would damage the control module and mechatronics unit.
- Disconnect electrical connections from starter.
- Remove starter - A -
- Clamp off gear oil cooler hoses using - 3094 and disconnect at gear oil cooler - A -
- Seal off gear oil cooler with clean plugs.
- Remove all engine/transmission connecting bolts which are accessible from above.
- Assemble support bracket 10 - 222 A together with brackets 10 - 222 A/1 and 10 - 222 A/3
- -1 - Shackle 10-222 A/l2
- Position support bracket on wheel housing flange.
- If there are hoses and cable connections in area of engine lifting eye for support bracket 10 - 222 A, remove these now.
- On right side, attach hook of spindle to engine lifting eye via a shackle 10-222 A12 - 1 -
- Take up weight of engine/transmission assembly via spindle.
- Raise vehicle.
- Remove center sound insulation fasteners - 1...3-
- Remove sound insulation (left side) -arrows -
- Remove front wheels.
- If installed, unscrew bracket for headlight range control in left wheel housing - arrows - and tie it up to one side.
- If installed, remove protective plate at bottom of transmission - arrows - .
- Press out right and left ball joints
- Remove bolts - 1 - and - 2 - and remove bracket - A -
- Unscrew nut - 1 - and push bracket - A - upward so it does not get stuck when transmission is lowered.
- Disconnect exhaust system at clamp - arrows
- Push clamp toward rear.
- Tie up exhaust system with a chain by engaging hooks 3004 in openings on underbody (if necessary remove plugs).
Note: The flexible pipe connection (de-coupling element) of the exhaust system must not be bent more than 10° otherwise it can be damaged.
Unbolt heat shield for axle shaft (right side) from bevel box.
- Unbolt axle shafts from transmission flanges.
- Lift axle shaft (right side) up and secure with wire.
- Move axle shaft (left side) clear toward rear and secure with wire.
- Mark position of driveshaft with flexible coupling in relation to bevel box flange.
- Remove driveshaft with flexible coupling from bevel box flange - arrows -
- Press driveshaft horizontally to rear as far as possible.
Caution:
^ When removing the transmission, make sure the seal in the driveshaft flange is not damaged. If the seal is damaged the driveshaft must be replaced.
^ Loosening bolts for the pendulum support, subframe causes the engine/transmission assembly to swing forward slightly.
- First remove bolts - A - and then bolts - B - on pendulum support.
- Remove pendulum support.
- Push engine/transmission assembly forward slightly and then pull driveshaft off bevel box.
- Place driveshaft above bevel box and secure it to prevent it falling.
- Remove subframe
- Unscrew bolts - 1 - and - 2 - at bracket for bevel box.
- Remove bracket -A - for bevel box.
From above
- Remove transmission console - A - (remove bolts - 1 - and -2-).
- Lower engine/transmission assembly using spindles until...
- ...distance -a- 100...110 mm between transmission housing and transmission mounting is attained.
To remove the direct shift transmission 02E the transmission support 3282 is set up together with the adjustment plate 3282/42.
- Align arms of transmission support according to holes in adjustment plate.
- Bolt support elements as illustrated to adjustment plate 3282/42.
- Place transmission jack under vehicle; arrow symbol on adjustment plate points in direction of travel/to front of vehicle.
- Align adjustment plate parallel with transmission.
- Secure support element to transmission using bolt - 1 -.
- Screw support element 3282/29 into transmission.
- Insert support element - 2 - into transmission and secure by tightening nut.
- Support transmission by lifting transmission jack from below.
- Remove remaining securing bolts between engine and transmission.
- Press transmission off dowel sleeves.
- Pull transmission off engine first from bevel box side and then from front side.
- Carefully lower transmission, making sure no wires are trapped.
- When lowering, change position of transmission via spindles on transmission support 3282.