Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine support bridge (10-222 A)
• Transmission support (3282)
• Adjustment plate (3282/43)
• Torque wrench (VAG 1331)
• Torque wrench (VAG 1332)
• Engine and transmission jack (VAG 1383 A)
• Insert pad for front fender (T40045)
• Grease for clutch plate splines (G 000 100 )
• Copper grease (Z 381 351 TE)
Procedure
• 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.
CAUTION!
• Follow steps required when disconnecting battery.
- With ignition switched off, disconnect battery Ground (GND) cable - arrow -.
- Remove engine cover - arrows -.
- Detach rubber seal from edges of wing mounting flanges.
- To avoid damaging edges of fenders with engine support bridge (10-222 A), insert wing compensation plates (T40045) on both sides between fender mounting flange and body panel underneath.
- Set up engine support bridge (10-222 A) with adapters (10-222/3) on fender mounting flanges.
- Engage spindles on engine lifting eyes as illustrated.
- Take up weight of engine using spindles.
- On vehicles equipped with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary heater to sound insulation.
- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
• - Item 3 - and - item B - can be disregarded.
- Remove bracket - arrow - for sound insulation.
- Unbolt heat shield - arrow - for drive axle (right side) from transmission.
- Unbolt drive axles (left and right) from transmission flange shafts.
• The flexible pipe connection (coupling element) on the front exhaust pipe must not be bent more than 10 degrees otherwise it can be damaged.
- Separate exhaust system at clamp - arrow - and slide clamp to rear.
- Remove bolt - 1 - and nut - 2 - and detach retaining bracket for front exhaust pipe.
Cabriolet
• On Audi Cabriolet vehicles the following steps are required in order to remove the three bottom engine/transmission bolts:
- Unbolt torque reaction support - arrows -.
- Remove nuts - 1 - on left and right sides, and swivel stabilizer bar - 2 - downward.
- Remove nut - 3 - on left and right engine mountings until bottom of nut is flush with end of stud - arrow -.
- Use engine support bridge (10-222 A) to lift engine just enough for nuts - 3 - to make contact with bottom surface of left and right consoles.
Continuation for All
- Remove three lower engine/transmission securing bolts - arrow -.
Cabriolet
- Lower engine back down.
Continuation for All
- Detach starter from engine/transmission and secure if necessary.
• Starter cables do not have to be disconnected.
- Drill a hole of 10.2 mm diameter - arrow - in supporting elements of transmission support (3282).
- To remove manual transmission 01X, set up transmission support (3282) with adjustment plate ( 3282/43) and place on engine and transmission jack (VAG 1383 A).
• The support elements (3282/49) - arrows A - and (3282/52) - arrows B - are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points toward the direction of travel.
• Adjustment plate can only be installed in one position.
- Align adjustment plate parallel to transmission.
- Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt - arrow - on right side to 20 Nm.
- Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt - arrow - on left side to 20 Nm.
- Remove bolts - 1 - and bolts - 2 -.
- Remove nuts - arrows - and detach tunnel crossmember.
- Lower transmission slightly using engine and transmission jack (VAG 1383 A).
- Disconnect electrical connector - arrow - for back up lamp switch (F4) and move electrical wire clear.
- Remove connecting rod - 2 - for selector rod.
- Remove push rod - 1 - by using an 8 mm hex key when removing bolt.
- Remove nut - arrow - and detach selector shaft lever from selector shaft.
- Remove upper engine/transmission bolts - arrows 1 - and - arrows 2 -. Please note that retaining brackets for wires/lines and coolant pipe may be secured on bolts - arrows 2 - (important for installation).
- If installed, remove retaining clips/cable ties together with Lambda probe wiring from transmission.
- Remove remaining engine/transmission bolts - arrow A - and - arrow B -.
- Press transmission off dowel sleeves and lower carefully with engine and transmission jack (VAG 1383 A) just far enough to gain access to slave cylinder.
• When lowering transmission, make sure hydraulic line to slave cylinder is not damaged.
- Remove slave cylinder from transmission - arrow - and secure with wire; do not open pipe/hose system.
CAUTION!
Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approximately 300 N.
- Lower transmission completely with engine and transmission jack (VAG 1383 A).
• When lowering transmission, make sure there is sufficient clearance to drive axles.
- Before carrying out assembly work, secure transmission to assembly stand, using holding fixture (VW 540 ). Refer to => [ Mounting Transmission on Assembly Stand ] Mounting Transmission on Assembly Stand.
- If you will be installing a new transmission instead of the one removed, the transmission mounting has to be transferred to the new transmission - arrows -.
Installing transmission. Refer to => [ Transmission, Installing ] Transmission, Installing.