Transmission, Removing and Installing
Transmission, removing and installing, 01E, 6 Spd. M/T AWD
Special Tools and Equipment:
^ 10-222A Engine support bridge
^ 2024A Engine Sling
^ 3282 transmission support
^ 3282/12 adjustment plate
^ V.A.G 1383 A Engine/transmission hoist
Removing
WARNING! Observe safety precautions when disconnecting the battery.
- Slide cover over the battery to the right (arrow 1) and pull it off upward (arrow 2).
See Caution before beginning repairs on the electrical system
- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
- Remove rear engine cover (arrows).
- Remove front engine cover (arrows).
- Remove cover -1- in engine compartment (right side).
- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
- Remove hose -4- of crankshaft housing ventilation from air duct -2-.
- Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
- Disconnect hose -1- from air duct.
Note: Illustration depicts air guide with the removed engine from rear
- Remove engine/transmission connecting bolts accessible from above.
- Position 10-222A engine support bridge on bolted flanges of fenders.
- Remove eyelet for 2024A engine sling.
- Insert bolt -1- in the center bore of 2024A Engine Sling and secure with a cotter pin.
- Attach bolt for 2024A engine sling at 10-222A engine support bridge spindle.
- Attach 2024A Engine Sling to sling clamps at front and rear of engine.
WARNING! Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
- Slightly pre-tension engine using engine support bridge spindle.
Vehicles with auxiliary heater:
- Remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
All:
- Remove the sound-proofing material (arrows).
- Unbolt bracket for noise insulation panel (arrow).
Note: The flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged..
- Disconnect exhaust system at double clamps -arrows-.
- Detach rear part of exhaust system on retaining loops and remove it.
Note: A second technician is required to remove the rear part of exhaust system.
- Remove heat shield for drive axle -arrows-.
- Remove bolts at flange of transmission/drive axle.
- Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
- Secure driveshaft -1- with wire (arrow) to heat shield.
- Remove V.A.G 1359/2 universal mount from V.A.G 1 383A engine/transmission jack and place a piece of wood -arrow- onto punch instead.
- Support tunnel cross member using V.A.G 1 383A engine/transmission lift.
- First remove bolts -1- and -2-, then bolts -3- and -4-.
- Release slowly the tunnel cross member using V.A.G 1383A engine/transmission hoist.
- Remove nuts -1- and -2-.
- Remove bolts (arrows) and remove tunnel cross member downward using transmission mount.
- Remove left and right heat shields for drive axles (arrows).
- Remove drive axles from transmission drive flange.
Note: Take care not to damage protective coating on drive axles.
- Raise transmission using punch of V.A.G 1383 A engine/transmission hoist high enough, so that a piece of wood (arrow) can be placed in between.
- Remove the three bottom engine/transmission connecting bolts (arrows).
- Lower transmission again.
- Unbolt starter -1- (arrows) and remove it from transmission bell housing.
- Remove remaining mounting bolts for engine/transmission. One bolt remains tightened by hand.
- Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.
- Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.
- Unbolt heat shield for engine speed (RPM) sensor.
- Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
- Disconnect connecting rod -2- of shift rod.
- Remove pivot rod -1-, to do this unbolt socket-head bolts.
- Remove nut -1- and pull transmission shift lever -2- from shift rod of transmission.
- Set up 3282 transmission support for removing manual transmission 01E all wheel drive using 3282/12 adjustment plate and V.A.G 1 383A engine/transmission hoist.
A - Attachments
Notes:
^ Attachments -A- are shown in schematic form, arrow -B- points in the direction of travel.
^ 3282/12 adjustment plate only fits in one position.
- Roll V.A.G 1383 A engine/transmission hoist underneath transmission. Arrow B go to Illustration V34-2931) on adjustment plate 3282/12 points in the direction of travel.
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Remove last mounting bolts for engine/transmission.
- Press transmission off dowel sleeves and lower carefully using V.A.G 1383 A engine/transmission hoist just enough for access to slave cylinder.
Note: When lowering the transmission, make sure the hydraulic line/hose to clutch slave cylinder is not damaged.
- Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect line.
- Lower transmission completely.
Note: Ensure freedom of movement of drive axles when lowering.
Installing
Installation is reverse of removal, noting the following:
Note: Always replace seals, gaskets and self-locking nuts.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines. remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
- Check clutch release bearing for wear and replace if necessary.
- Coat contact surface of clutch release lever plunger with a thin layer of copper grease, e.g. Z 381 351 TE.
- If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-195-KD1-01.
- 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring.
- If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
- All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid using a tap.
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
- Place intermediate plate onto the dowel sleeves on engine flange.
- Tie electrical wires off to the side before installing, so that they are not pinched between engine and transmission.
- Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow).
- Secure slave cylinder with a new bolt (arrow).
- Install starter and secure connecting bolts for engine/transmission on left and right side.
- Install connecting rods and pivot rods for shift mechanism.
- Place a piece of wood (arrow) onto punch of V.A.G 1383 A engine/transmission hoist and raise transmission slightly.
- Tighten the three bottom engine/transmission connecting bolts (arrows).
- Lower transmission again.
- Guide the tunnel cross member with loosely inserted transmission mount over front exhaust pipes.
Note: The flexjoint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Place a piece of wood (arrow) onto punch of V.A.G 1383 A engine/transmission hoist and raise tunnel cross member and transmission slightly.
- Next, tighten bolts -1- to -4- hand-tight.
- Release slowly the V.A.G 1383 A engine/transmission hoist.
- Tighten bolts for tunnel cross member.
- For tension-free installation, raise transmission using punch of V.A.G 1383 A engine/transmission hoist high enough so that a piece of wood -1- can be placed in between.
- Tighten bolts (arrows) for transmission mount.
- Slowly lower transmission again.
- Tighten nuts -2- and -3-.
- Bolt drive axles on drive flange.
- Secure driveshaft to transmission.
- Check adjustment of shift mechanism and adjust if necessary.
- Install and adjust exhaust system free of stress.
- Check transmission oil level in manual transmission.
See Caution for disconnecting Telematics battery
- Observe safety precautions after connecting the battery.
Tightening torques
Securing engine/transmission for manual transmission with All Wheel Drive (with intermediate plate)
A: Alignment Bushing
