Transmission, Removing
Transmission, Removing
- Follow repair instructions. Refer to => [ General Repair Information ] General Repair Information.
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A)
• Transmission Support (3282)
• Adjustment Plates (3282/52)
• Drip tray (VAS 6208)
• Socket (T40058)
• Bolt (3282/50)
• Engine Support Bridge (10 - 222 A)
• Hooks (10 - 222 A /2)
• Shackle (10 - 222 A /12), quantity: 2
• Adapter (10 - 222 A /21), quantity: 2
• Hose Clamps Up to 25 mm Dia. (3094), quantity: 2
• Support Connectors (T40092/4), quantity: 2
• Four-Edge Tubes (T40091/1)
• Support Connector (T40091/2)
• Support Connector (T40091/3)
• Crossmember (T40092/1)
• Support Connector (T40092/2)
• Support Connector (T40092/3)
• Pry Lever - RMV Outside Mirror (80 - 200)
• Reinstall cable ties that were loosened or cut off during removal at same locations during installation.
Follow the instructions for disconnecting the battery.
• The battery may only be disconnected when the ignition key is inserted so that the front wheels can still be turned.
• Release the electric parking brake before disconnecting the battery so that the driveshaft can still be rotated while it is being removed from vehicles with all wheel drive.
- Turn off the ignition.
- Remove the cover - arrows - for the trunk trim assembly to the right.
- Remove cover - 1 - over the battery.
• Ignore - 2 -.
- Disconnect the battery ground (GND) cable - arrow -.
- Remove the engine covers - 1 - and - 2 - upward.
- Remove the rubber seal - 1 - on the radiator tank cover.
- Remove the radiator tank cover - 2 - and - 3 -.
- Remove the cover for the left strut tower, taking out the nuts - 1 - and expansion clip - 2 -.
- Remove the bolts - arrows -.
- Swivel the bracket for the cooling agent pipe to the side.
• To prevent damage to the air conditioning hoses as well as the refrigerant lines/hoses, make sure that the lines and hoses are not overstretched, kinked or bent.
- Remove the cover for the right strut tower, taking out the expansion clips - 1 - and loosening the screw connection - 2 -.
- Pull off the cover off of the retainer - arrows -
- Remove air guide pipe - arrows -.
- Turn the rear fastening screws - 4 - for the left and right strut brace.
- Attach the (10 - 222 A /21) to the left and right strut towers.
• The supports are marked for the left and right side of the vehicle.
• The center mounting point - 2 - of the supports is put on the front strut tower bolts.
• The (10 - 222 A /21) are fastened with rear strut tower fastening bolts - 3 -.
• The knurled screws - 1 - must be turned to the bottom so that the support plate rests on the strut tower.
- Assemble the (10 - 222 A /21) with two rotational connectors similar to illustration and attach to (T40091/3).
- Tighten the bolts - A -.
• The engine support bridge will be secured.
- Remove the strut mount - arrow - from the engine.
- Insert (T40091/1) in (T40092/4).
• Allow both (T40091/1) to stick out far enough so that both rear spindles can be fastened securely.
- Install an additional hook (10 - 222 A /10) and (T40092/4) on right (T40091/1) as shown in the illustration.
- On the left (T40091/1), install the (T40092/4) as shown in the illustration.
- Lift the vehicle.
- Loosen quick-release connectors - 1 to 3 - and bolts - 4 - and remove noise insulation.
- Remove the cross brace for the sound insulation on the subframe - arrows -.
- Fasten the (T40092/2) to the lower left mounting location of the longitudinal member with two bolts - arrows -.
• The lower (T40092/2) is secured with two bolts - arrows -, M10 x 30 (10.9 DIN 6921), tightening specification 40 Nm.
- Secure (T40092/3) to lower right longmember mount with two bolts - arrows -.
• The (T40092/3) is secured with two bolts - arrows -, M10 x 30 (10.9 DIN 6921), tightening specification 40 Nm.
- Push both (T40091/2) upward between the front end and the engine.
• Make sure the (T40091/2) have sufficient clearance.
• When guiding the (T40091/2) through, be careful not to damage any other components.
- Guide the (T40091/2) from below through the openings of the (T40092/4).
- A second technician must slide the lower crossmember (T40092/1) sideways through the opening for the lower left counter support (T40092/2) and lower right counter support (T40092/3) and secure the supports (T40091/2).
- Push the securing pins - 1 - all the way through the holes in the (T40091/2).
• The safety bolts - 1 - must be inserted all the way.
• Both circlips - 2 - for the bolts - 1 - must be pressed down, so that the bolts are secured against falling out.
• If the bolts are not properly secured, the engine and transmission can fall out if the subframe comes loose!
- Tighten the bolts - arrows -.
- Push the securing pins - 1 - all the way through holes in the (T40092/4).
• Both (T40091/1) must be aligned horizontally.
• The safety bolts - 1 - must be inserted all the way.
• Both circlips - 2 - for the bolts - 1 - must be pressed down, so that the bolts are secured against falling out.
• If the bolts are not properly secured, the engine and transmission can fall out if the subframe comes loose!
- Attach both rear spindles with one (10 - 222 A /12) each on the engine intake mount.
- Fasten front spindle to engine lifting eye with (10 - 222 A /2).
- Slightly pretension engine support bridge spindle.
- Tighten the bolts - arrows -.
• The engine support bridge will be fixed and secured.
- Remove bolts - 2 - and then remove the crossmember.
- Loosen the nuts - arrow - for the front transmission housing.
- Remove the left and right bolts for the front transmission housing - arrows A -.
- Disconnect the connector - 2 - from the vehicle level sensor on both sides of the vehicle.
- Remove the coupling rods - 1 - from the control arm on both sides of the vehicle.
- Note the position of the subframe on the body with a felt-tip marker.
- Place (V.A.G 1383 A) under subframe and lightly press against it.
- Remove left and right engine mounting bolts - arrows -.
- Mark installation position of subframe on longmembers with a felt-tip pen.
- Remove the bolts - 1 - and - 4 -.
- Remove the bolts - 2 - and - 3 - crosswise in stages.
- Slowly lower the subframe together with engine carrier.
- Remove the engine carrier.
- Remove the right engine support with engine mount.
- Remove the starter.
- Insert the guide pin on (T40058) so that large diameter - arrow 1 - faces toward engine. The small diameter - arrow 2 - faces the adapter.
- Counter hold the crankshaft with the (T40058) and loosen the torque converter bolts.
• Ignore - arrow -.
- Remove the 6 internal Torx(R) bolts - arrow - of the torque converter in the opening of the removed starter (turn crankshaft 1/3 revolution further for each bolt).
- Disconnect the exhaust system at the clamping sleeves - 1 - and - 2 -.
• To prevent damage, never bend the decoupling element of the front exhaust pipe more than 10°.
- Remove the driveshaft heat shield - A - - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.
- Tie up front driveshaft to body.
Lower the Back of the Transmission:
- Move the (V.A.G 1383 A) and (3282) under the transmission.
- Place both front (3282/52) against the transmission oil pan.
- Insert the third (3282/48) into the hole in the back of the transmission housing.
- Mark the installation location of the tunnel crossmember on the body.
- Remove the left - 1 - and right - 2 - transmission bolts on tunnel crossmember.
- Remove the transmission tunnel crossmember from the body - arrows -.
- Carefully the lower rear of engine/transmission assembly slightly over spindles.
To prevent damage from occurring, it is very important to pay attention to everything in the engine compartment.
- Remove the rear tunnel crossmember.
- Remove the front transmission supports with transmission mounts.
- Remove the noise insulation in the left and right wheel housing - arrow -.
- Remove the heat shield from the transmission above the drive axle on the left and right - arrows -.
- Remove the left and right drive axle from the transmission flange.
- Uncover the electric cable for the heated oxygen sensor 2 (G108) for the catalytic converter.
- Remove the catalytic converter with left front muffler from the exhaust manifold - arrows -.
- Remove the electrical connector - 3 - (brown) for the oxygen sensor 2 after catalytic converter (G131) after the catalytic converter and uncover the electric cable.
- Remove the nuts - arrows - on the holding straps for the main catalytic converter.
- Remove the bolts - arrow - on the straps for the exhaust pipes.
• Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.
- Remove the catalytic converter with left front muffler.
- Loosen the nuts from the catalytic converter with right front muffler to the exhaust manifold - 1, 2 and 3 - so that the catalytic converter is loose.
• The catalytic converter with right front muffler does not need to be removed due to the poor accessibility of the heated oxygen sensor.
- Remove the bolts - 1 - on the straps for the right exhaust pipes.
- Remove shield from lever/selector shaft.
- Remove the selector lever cable ball socket - 1 - from the selector shaft lever - 3 - using the (80 - 200)
- Unclip the locking plate - 2 - on the selector lever cable bracket.
- Uncover the shift selector cable.
- Tag the ATF cooling hoses to avoid mix-ups when re-installing.
- Clamp off the ATF cooling hoses to the ATF cooler using (3094).
- Place the (VAS 6208) under the transmission.
- Remove the coolant hoses from ATF cooler.
- Disconnect the connector on the transmission by swiveling the rotational fastener counter-clockwise - arrow -.
- Remove the engine speed sensor (G28) - arrow - on the transmission.
- Remove the bracket for the electrical connector from underneath the transmission.
- Uncover all electrical wires and hoses on the transmission housing.
- Mount the (3282) on the (V.A.G 1383 A).
- Install the (3282/52) on the (3282) as illustrated.
- Align the arms of the transmission support to correspond with the holes in the adjustment plate.
- Attach the support elements on the adjusting plate as illustrated.
• The bolts (3282/50) have a lateral flat portion - arrow -. When inserting into transmission, the flattened side must face toward the oil pan.
• The arrow symbol on the (3282/52) points in the direction of travel.
- Move the (V.A.G 1383 A) and (3282) under the transmission.
- Align the (3282/52) so they are parallel to the transmission by adjusting the (3282).
- Bolt the left front transmission support - 1 - at the threaded hole with an additional washer - A - between the transmission and the support.
• Without the washer - A - the transmission connector - B - will be damaged.
- Securely mount the support to the threaded hole at back left with a bolt - 2 -.
- Brace the transmission on the right front in the bolt connection - arrow 1 - of the oil pan.
- Put the (3282/50) with the flat side - arrow - to the transmission oil pan in the mount bore on the back right of the transmission housing - arrow 2 -.
• The flattened side of the (3282/50) must face toward transmission oil pan, so that it does not bend or become damaged.
• Replace the transmission fluid pan if it is damaged.
- Remove the bolts - 1 - through - 10 -.
- Pry apart the torque converter from the drive plate with a tire lever - arrow -.
- Pry apart the transmission from the alignment sleeves and carefully set it down.
- Lower the transmission by the appropriate adjustment of the (3282) on the rear edge.
- Guide the transmission sideways to the back/downwards.
Pay attention to transmission clearance when lowering.