Transmission, Removing (Vehicles With 6-Cylinder Engine)
Transmission, removing (vehicles with 6-cylinder engine) - 6 Spd. Manual Transmission 02X All Wheel Drive
Special tools, testers and auxiliary items required
^ Support bracket 10 - 222 A
^ Transmission support 3282
^ Adjustment plate 3282/43
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Engine/transmission jack V.A.G 1383 A
Special tools, testers and auxiliary items required
^ Insert pad for front fender T40045
^ Lifting aid 2024 A
^ Grease for clutch plate splines G000100
^ Copper grease Z381351TE
Note:
^ 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) strap - arrow -.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
- Remove cover - 1 - on left side of engine compartment.
- Unfasten coolant expansion tank - arrow -.
- Disconnect electrical wiring for Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
- Tie coolant expansion tank to one side, leaving coolant hoses - 1 -, - 2 - and - 3 - connected.
- Remove cover - 1 - on right side of engine compartment.
- Remove bolts - arrows - from solenoid valve mounting plate - 3 -.
- Disconnect air intake hose - 1 - from mass air flow sensor.
- Pull hose - 4 - for crankcase breather system off air duct - 2 -.
- Remove bolt - arrow - and disconnect air duct - 2 - from throttle valve control module.
- If installed, disconnect hose - 1 - from air duct.
Note:
^ In the illustration, the air duct is shown from the rear and with the engine removed.
- Remove engine/transmission securing bolts which are accessible from above.
- Disconnect connectors - 1 to 4 - from retainer at left of bulkhead.
- Disconnect electrical connectors - 1 - and - 4 -.
- Move Lambda probe wires clear.
- Remove retainer for connectors.
- Remove nut - 1 - (access from above), connecting left front exhaust pipe with exhaust manifold.
Note:
^ In the illustration the engine has been removed.
- Remove rubber seal from edges of fender mounting flanges.
- To avoid damaging edges of fender panels with support bracket 10-222 A, insert insert pad for front fender T40045 on both sides between fender mounting flange and body panel underneath.
- Set up support bracket 10 - 222 A on fender mounting flanges.
- Remove eye of lifting tackle 2024A.
- Re-insert pin - 1 - in middle hole on lifting tackle and secure it with split pin.
- Hook pin on lifting tackle 2024A onto spindle on support bracket 10 - 222 A.
- Hook lifting tackle 2024A into lifting eyes at front and rear of engine.
CAUTION!
Support hooks and locking pins on lifting tackle must be secured with retainers - arrows - in illustration.
- Slightly pretension engine with spindle of support bracket.
- On vehicles equipped with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary heater to sound insulation.
- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
- If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.
- Remove bracket for sound insulation - arrows -.
- Remove heat shield - arrow - for drive axles (left and right).
- Remove drive axles from flange shafts, lift clear and secure.
Note:
^ Make sure you do not damage surface coating on drive axles.
- If installed, remove front cross member - 1 to 4 -.
- Disconnect exhaust system at clamps - arrows -.
- Remove front exhaust pipe with catalytic converter (left-side).
- Remove bracket for exhaust pipe (right front) from transmission.
- If installed, remove heat shield for drive shaft - arrows -.
- Remove bolts - arrows - at transmission/drive shaft flange.
- Slide drive shaft together toward rear final drive. The constant velocity joints can be moved axially.
- Tie drive shaft to side.
- Remove nuts - 1 - at bottom of engine mountings (left and right).
- If installed, unclip operating rod for left front level control system sensor G78 from lower transverse link - arrow -.
- Before loosening subframe, use testing mandrel 3393 to check whether holes - 1 - and - 2 - are aligned.
If holes are not aligned, a wheel alignment has to be performed after installing the subframe.
- Remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
- Lower subframe at front.
- Remove lower engine/transmission securing bolts - arrows -.
- Temporarily secure subframe again.
Temporary tightening torque:
1 - approx. 100 Nm
2 - approx. 70 Nm
3 - approx. 70 Nm
CAUTION!
Do not replace bolts yet or tighten to their final torque. This will be done when installing the transmission.
- Remove connecting rod - 2 - for selector rod.
- Disconnect push rod - 1 - by removing hex socket head bolt.
- Disconnect electrical connector - arrow - for Back-up light switch F4 and move electrical wire clear.
- Remove nut - arrow - and detach selector shaft lever from selector shaft.
- If installed, remove Engine Speed (RPM) sensor G28 from left side of transmission - arrow - and lay aside.
- Remove starter from engine/transmission and secure if necessary.
Note:
^ Starter cables do not have to be disconnected.
- Drill a hole of 10.2mmdia. - arrow - in the supporting elements of transmission support 3282.
- To remove transmission set up transmission support 3282 with adjustment plate 3282 /43 and place on engine/transmission jack V.A.G 1383 A.
Note:
^ 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 correct position.
- Align adjustment plate parallel to transmission.
- Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt M10x20 - arrow on right side - to 20 Nm.
- Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt M10x20 - arrow on left side - to 20 Nm.
- Remove bolts - 1 - and then bolts - 2 - at cross member.
- Remove nuts - arrows - and detach cross member.
- Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.
- Press transmission off dowel sleeves and lower carefully using engine/transmission jack V.A.G 1383 A just far enough to gain access to the slave cylinder.
Note:
^ 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 line/hose system.
CAUTION!
Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.
- If installed, open cable ties - arrows A and B -, unclip Lambda probe cables at the side - arrows C - and move cables clear.
- Lower transmission.
Note:
^ When lowering transmission, make sure there is sufficient clearance to drive axles.
- Before carrying out assembly work, secure transmission to assembly stand, using engine and transmission support VW 540.
- If installing a new transmission instead of the one removed, the transmission mounting has to be transferred to the new transmission - arrows -.
Installing transmission