Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Engine Support Adapter (10 - 222 A /3)
• Spindle (10 - 222 A /11)
• Ring Spanner Insert AF16 (V.A.G 1332/14)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Puller for Gear Shaft Linkage (T40160)
• Gearbox Support (T40173)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Release Tool f/ Rev. Light Switch Conn. (T40138)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Connector (T40091/3)
Removing
- Turn off the ignition and remove the key.
- Disconnect the battery.
Risk of damaging electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Remove the rear engine cover - arrows -.
- Remove the left and right front wheels.
- Remove the left and right noise insulation - 1 - inside the wheel housing.
- Loosen the fasteners - 1, 2, 3 and 4 - and remove the noise insulation.
- Remove the subframe crossbrace.
The suspension components could be damaged.
Do not rest the vehicle on its wheels if the subframe, the steering gear or the subframe crossbrace are not installed correctly.
Do not support the vehicle on the subframe or on the subframe crossbrace (for example using a floor jack or something similar).
- Remove the steering intermediate shaft from the steering gear and push it upward.
The airbag spiral spring could be damaged.
• Only disconnect universal joint from the steering gear if the front wheels are in the straight-ahead position.
• Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.
- Remove the left and right front muffler.
- Remove the bulkhead plenum chamber.
- Remove the nuts - arrows - and the bolt - 1 - and push the catalytic converter to the right side.
• The illustration shows the installation position with the engine removed.
- Remove the bolts - 2 through 6 - connecting the engine to the transmission. They are accessible from above.
- Secure the right catalytic converter loosely using a nut so it does not fall down.
- Position the (10 - 222 A) with (T40091/3) on the left and right suspension strut towers as shown in the illustration.
- Engage the (10 - 222 A /11) in the right engine lifting eye.
- Install the additional (10 - 222 A) parts as illustrated. Place the (T40093/3) on the notches in the longitudinal member.
- Engage the (10 - 222 A /11) in the left front engine lifting eye.
- Disconnect the connector - 2 - from the Engine Speed (RPM) sensor (G28) and free up the wire.
• Ignore - 1 -.
- Remove the bolts - arrows - and remove the driveshaft heat shield (if equipped) for the driveshaft - A -.
- Block the driveshaft using the (T10172) and (T10172/5) so that it does not turn, too.
• For vehicles with "the driveshaft connected on the transmission side", the rear final drive is counter held the same way.
- Remove the gearshift shaft - 1 - and then move the gearshift lever - 2 - forward in direction of - arrow - into 6th gear.
- Remove the lower cover - 1 - from the transmission - arrow -.
- Turn the clutch module over both front wheel 60° in direction of engine rotation and remove the six drive plate bolts - arrow -.
Driveshaft Bolted on the Transmission Side
- Remove the bolts that connect the driveshaft to the transmission by counter holding them with the (T10172) and (T10172/5).
- Press the driveshaft together with the rear final drive; the universal joint is able to slide axially.
- Secure the driveshaft to the side.
Driveshaft Connected on the Transmission Side
- Remove the driveshaft.
All Vehicles
- Remove the bolts - arrows - and then remove the heat shield from the right drive axles.
• The illustration shows the installation position with the transmission removed.
- Remove the bolts - arrows - and the left drive axle heat shield.
• The illustration shows the installation position with the transmission removed.
- Remove left and right drive axles from transmission flange shafts.
- Remove the bolt - 2 - and secure the clutch slave cylinder sideways in the engine compartment.
The clutch slave cylinder could be damaged.
• Do not press the clutch pedal after the clutch slave cylinder has been removed.
- Remove the nut - 1 -.
Danger of causing damage to the gearshift shaft inside the transmission.
• Do not pry off the transmission shift lever - 1 - using a pry bar or hit it with a hammer.
• The only tool that is allowed to be used to pull the transmission shift lever off is the (T40160).
- Mount the (T40160) and remove the gearshift rod - 1 -.
- Remove the bolt - 1 - press the retaining tab off the transmission and tilt it back - arrow -.
- Position the (V.A.G 1383 A) and the (T40173) under the transmission and secure it with the tensioning strap - 1 - as illustrated.
- Remove the starter bolt - 4 - from the engine side.
- Remove the starter from the transmission and leave it in the installation position.
• The starter cables - 2 and 3 - do not need to be loosened.
• Ignore - 1 -.
- Remove the remaining bolts - 7 through 11 - that attach the engine to the transmission.
- Remove the bolts from the tunnel crossmember - arrows -.
- Lower the transmission using the (V.A.G 1383 A) first to dimension - a -.
• Dimension - a - = maximum 100 mm (3.93 inches).
- Slightly tension the threaded spindles on the (10 - 222 A).
- Disconnect the connector - 1 - using the transmission range gear recognition switch (F208) using the (T40138) and free up the wire.
- Remove the push rod bolt - 2 -.
- Remove the connecting rod bolt - 3 -.
- Press the transmission off the engine and lower it carefully using the (V.A.G 1383 A).
- If the transmission removed is being replaced, then the following components must be changed:
• Removing the clutch module if necessary.
• Tunnel crossmember with the transmission mount and transmission support. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.