Removal and Replacement
Transmission, 4.2L MPI
Special tools, testers and auxiliary items required
• Engine support bridge (10-222 A)
• Shackle (10-222 A/12)
• Hose clamps up to 25 mm diameter. (3094)
• Transmission support (3282)
• Adjustment plate (3282/48)
• Engine/transmission jack (V.A.G 1383 A )
• Bracket (30-211 A)
• Pin (3282/50)
• Fender insert pads (T40045)
• Adapter (T40058)
• M10x20 bolt
Removing
• General repair notes. Refer to => [ General Repair Information ] General Repair Information.
• Rules of cleanliness for working on automatic transmissions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.
• Heat shield sleeves removed during removal should be placed in the same location when installing.
- Place selector lever in position "P".
CAUTION!
Observe procedures for disconnecting battery.
- Slide cover over the battery to the right - arrow 1 - and pull it off upwards - arrow 2 -.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
- Remove left cover - 1 - in engine compartment.
- Clamp off coolant hose - 2 - with Hose Clamps Up to 25 mm dia. (3094) and remove from coolant reservoir.
- Remove coolant reservoir - arrow -.
- Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch (F66) at bottom of reservoir and lay aside coolant reservoir with coolant hose - 1 - connected.
- If necessary, seal connector with proper plugs.
- Remove electrical harness connectors - 1 through 4 - from bracket at left of bulkhead.
- Disconnect electrical connectors - 1 -, - 3 - and - 4 -.
- Remove bracket on bulkhead.
- Remove heat shield sleeve on wiring harness and expose wiring harness.
- Expose oxygen sensor wiring below.
- Remove right cover - 1 - in engine compartment.
- Remove air guide hose - arrows -.
- Remove connectors - 1 through 4 - from bracket at right of bulkhead.
- Disconnect electrical connectors - 2 - and - 4 -.
- Expose oxygen sensor wiring below.
• Mark oxygen sensor wire securing points so that they can be secured again in the same places when installing.
- Secure shackle (10-222 A/12) at right rear engine lifting eye.
• Disregard - 1 -.
- Pull off sealing rubber at bolted flanges of fender.
- To prevent damage to bolted flanges of fender when using engine support bridge (10-222 A), insert fender insert pads (T40045) on both sides between bolted flange of fender and web plate lying beneath.
- Attach the engine support bridge (10-222 A) and adapters (10-222 A/3) to the bolted fender flanges as illustrated.
- Attach the engine support bridge (10-222 A) spindles at the front to the engine lift eye and in the back on the shackle (10-222 A/21).
- Take up weight of engine on support bar spindles a little, but do not lift.
- Remove both front wheels.
- Loosen quick-release connectors - 1 -, remove screws - 2 - and remove noise insulation.
- Remove noise insulation bracket - arrows -.
- Remove wiring harness bracket at right of engine bracket - arrows -.
- Remove level control sensor actuator rod on the lower control arm - arrow - if equipped, or disconnect the upper connector on the actuator rod.
- Remove left and right bolt - 2 -.
• Ignore - 1 - and - 3, 4 and 5 -.
- Remove left and right nuts - 1 through 4 - for the stabilizer bar mounting and then remove the stabilizer bar.
- Remove left and right bolts - 3 - for the transmission mount - B - to the subframe - C -.
- Before loosening subframe, check with Testing Mandrel (3393) whether holes - 1 - and - 2 - align.
If this is not the case, vehicle alignment must be carried out after installing subframe.
- Remove bolts - 1 through 4 - and lower subframe.
• The subframe can remain hanging on the cross members and does not need to be removed completely.
• To prevent damage, decoupling element in the front exhaust pipes must never be angled by more than 10°.
- Disconnect exhaust system at double clamps - arrows -.
- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Push driveshaft toward rear final drive. CV joints can be moved axially.
- Tie driveshaft up and toward the side to the heat shield - arrow -.
- Disconnect 16-pin connector - 2 - on the transmission by moving the securing lever and turning the rotating screw counter-clockwise.
• Disregard - 1 -.
- Remove head shields - arrow - for left and right drive axles.
- Remove left and right drive axles from the transmission flange.
• Make sure drive axle protective coating is not damaged.
- Remove right refrigerant line bracket - arrow -.
- Disconnect electrical connector - 1 -.
- Remove bolts - arrows - and remove engine support and engine mount.
- Remove Ground (GND) cable - 5 -.
- Remove electrical wires - 3 - and - 4 -.
- Remove nut - 1 - and bolt - 2 -.
- Remove starter.
- Insert guide pins of the adapter (T40058) so that the large diameter - arrow 1 - faces toward the engine. The small diameter - arrow 2 - faces toward the adapter.
- To loosen the torque converter bolts, counterhold the crankshaft with adapter (T40058).
- Remove the 3 torque converter bolts in the opening of the removed starter (turn crankshaft 1/3 revolution further for each bolt).
- Remove lower engine/transmission bolts - arrows -.
- If necessary, mark position of mounting bracket for selector lever cable relative to transmission housing for reinstallation - arrows -.
- Loosen clamps for the ATF pipes attached to the transmission and engine. Refer to => [ ATF Cooling Lines ] ATF Cooling Lines.
- Lower engine/transmission subframe as far as possible by the spindles on engine support bridge.
CAUTION!
Do no bend or pinch the pipes or destroy any components when lowering the engine/transmission assembly.
• Mark oxygen sensor wire securing points so that they can be secured again in the same places when installing.
- Remove bolt - arrow - at left exhaust pipe strap.
- Remove left front exhaust pipe/manifold nuts - 1 to 3 -.
• Shown in illustration with engine removed.
- Remove front exhaust pipe from left exhaust manifold.
- Remove front exhaust pipe.
- Remove bolt - 2 -.
- Remove heat shield - B -.
- Remove bolt - 1 -.
- Remove Engine Speed (RPM) Sensor (G28) - A - from the transmission.
• The Engine Speed (RPM) Sensor (G28) is located inside the transmission bell housing on the left side at the top.
- Remove bolt - arrow - at right exhaust pipe strap.
- Remove right front exhaust pipe/manifold nuts - 1 to 3 -.
• Shown in illustration with engine removed.
- Remove front exhaust pipe.
- Remove left and right bolts on the transmission supports - 2 - and remove heat shield - B -.
- Remove bolts - 1 -.
- Remove complete transmission support - A - and mount form the transmission.
- Press ball socket - 1 - of the selector lever cable off from the selector shaft lever using the pry lever ( 80-200).
• Take care not to bend or kink selector lever cable.
• Disregard - 2 -.
- Mount the transmission support (3282) on the Engine/Transmission Jack (V.A.G 1383 A).
- Place the adjustment plate (3282/48) on the transmission support (3282), as shown in the illustration.
- Align the arms of the transmission support to correspond with the holes in the adjustment plate.
- Attach support elements on adjustment plate, as illustrated.
- Make sure the bolt (3282/50) is installed on the rear right side.
• The Pin (3282/50) has a flattened part on the side - arrow - that must face toward oil pan when inserted in transmission.
- Place Engine/Transmission Jack (V.A.G 1383 A) with transmission support (3282) under transmission.
• The arrow symbol on the adjusting plate points in the direction of travel.
- Align adjustment plate in parallel with transmission.
- Secure mount to threaded hole at back left of transmission with an M10x20 bolt - arrow 1 -.
- Insert flattened Pin (3282/50) into mounting hole at right rear of transmission housing - arrow 2 -.
CAUTION!
• The flattened side of the pin must face toward transmission oil pan, so that it does not bend or become damaged.
• If the transmission oil pan is damaged, it must be replaced.
- Insert pin in left front mounting hole on transmission housing - arrow 2 -.
- Place pin in housing recess at right front of differential housing - arrow 1 -.
- Place drip tray underneath to collect oil.
- Remove bolts - 2 -.
- Remove ATF cooling lines from the transmission.
- Seal off lines and transmission with clean sealing pugs to prevent ATF from escaping.
- Remove remaining connecting bolts between engine and transmission.
- If necessary, lower transmission slightly over spindles again.
- Press torque converter off engine drive plate using pry bar - arrow -.
- Press transmission off engine.
- Lower the transmission at the rear edge by adjusting the transmission support (3282) accordingly.
- Guide transmission out at an angle (rearward/downward).
• Pay attention to drive axle clearance when lowering.
- Secure torque converter in transmission against falling down using Bracket (30-211 A).
Installing
• All cable ties must be installed in their original positions.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory.
• Heat shield sleeves must be installed in their original positions.
• Replace self-locking nuts.
- Before installing transmission make sure the torque converter is correctly installed in the transmission:
• With torque converter installed correctly, the distance between contact surfaces on threaded holes on converter and torque converter bell housing contact surface is at least 19 mm.
CAUTION!
If the torque converter is not properly installed, the drive lugs on the torque converter and the ATF pump will be severely damaged when the transmission is attached to the engine.
- Before installing the transmission, make sure the alignment sleeves - A - are correctly positioned on the cylinder block, if necessary install.
- If an intermediate plate was equipped between the engine and transmission, reinstall it in the same position.
- Make sure that no wires become pinched when connecting the engine and transmission.
CAUTION!
Before and during fastening the bolts of the engine/transmission flange, check that the torque converter can still be turned behind the drive plate. If the torque converter cannot be turned, it must be assumed that it has not been installed properly and that the drive plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.
- Mount transmission to the engine.
- To secure torque converter to drive plate, use new ribbed bolts. Use original bolts only.
- Insert guide pins of the adapter (T40058) so that the large diameter - arrow 1 - faces toward the engine. The small diameter - arrow 2 - faces toward the adapter.
- To tighten the torque converter bolts, counterhold the crankshaft with adapter (T40058).
- Install the 3 bolts of the torque converter in the opening of the removed starter hand-tight at first (turn crankshaft 1/ 3 revolution further for each bolt).
- Tighten bolts of the torque converter to the specified torque (turn crankshaft 1/3 revolution further for each bolt).
- Install Engine Speed (RPM) Sensor (G28) - A - inside the transmission bell housing at the top and on the left side and tighten the bolt - 1 -.
- Install heat shield - B - and tighten the bolt - 2 - (transmission/engine connection ).
- Insert ATF cooling lines - A - and - B - all the way into the transmission and tighten the bolt - 2 -.
- Press selector lever cable - 1 - onto selector shaft lever - 3 -.
- Install starter.
- Install transmission supports and transmission mount. Refer to => [ Left and Right Transmission Mount and Transmission Support ] Service and Repair.
- Install front exhaust pipes.
If holes - 1 - and - 2 - aligned during removal when measured with Testing Mandrel (3393):
- Install subframe, observing tightening sequence..
If holes - 1 - and - 2 - did not align when measured with Testing Mandrel (3393):
- Only tighten subframe bolts to tightening specifications, not to additional torque (only tighten bolts after alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Clean ATF pipes and cooler. Refer to => [ ATF Cooling Lines and Cooler, Cleaning ] 09LA Transmission.
- Secure ATF pipes and transmission on engine. Refer to => [ ATF Cooling Lines ] ATF Cooling Lines
- Secure selector lever cable bracket - arrows -.
- Fasten driveshaft to the transmission.
- Secure driveshaft heat shield - A - - arrows -.
- Install exhaust system tension-free.
- Drive axle, installing on flange shaft => Steering and Suspension Steering and Suspension
- Install head shields - arrow - for left and right drive axles.
- Adjust selector lever cable. Refer to => [ Selector Lever Cable, Checking and Adjusting ] Selector Lever Cable, Checking and Adjusting.
- Check oil level in front final drive. Refer to => [ Front Final Drive ] Service and Repair
- Observe procedures for connecting battery.
- Check ATF level. Refer to => [ ATF, Checking Level and Correcting ] ATF, Checking Level and Correcting.
- Perform an axle alignment if necessary.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use degreased parts.
* Replace bolts.
* Use only Original bolts.
Transmission flange face
A: Centering alignment sleeves
Engine to transmission mount:
* Also secures the starter.
Transmission to engine mount:
* Also secures a heat shield.
