Transmission, 3.0L TDI, Removing

Transmission, 3.0L TDI, Removing

Special tools, testers and auxiliary items required

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Engine Support Bridge (10 - 222 A)

• Engine/Transmission Jack (V.A.G 1383 A)

• Oil Collecting And Extracting Device (V.A.G 1782)

• Plug Set, Engine (VAS 6122)

• Counterhold Tool (T10172) with (T10172/5)

• Adapter (T40058)

• Transmission Support (T40173)

• Bolt M8x35 and washer outer diameter 25 mm

Preparing the Transmission Support (T40173):





- The bracket attached to - 1 - must be removed.

- The bracket - 2 - must be turned so that the longer side faces upward as illustrated.

Removing

CAUTION!
Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Position the front wheels so they are straight.

- Switch ignition off and remove ignition key.

- Disconnect the Ground (GND) cable - arrow - from the battery terminal.





- Extract the power steering hydraulic oil from the reservoir using the Oil Collecting and Extracting Device (V.A.G 1782).

- Remove engine cover - arrows -.





- Remove left and right front wheels.





- Remove left and right drive axle cover - 1 - in the wheel housing.

- Remove noise insulation - 1 - and - 2 -. Refer to => Body Exterior 66 Description and Operation.





- Remove tower brace.





- Remove front exhaust pipe. Refer to => Engine Mechanical 26 Description and Operation.





- Remove bolt - arrow - for the ATF lines.





- Remove particulate filter. Refer to => Engine Mechanical 26 Description and Operation.





• To collect escaping ATF, lay a clean cloth under the separating point.

- Remove the bolts - arrows - and disconnect the ATF pipe - 1 - from the transmission.





• Disregard items - 2 and 3 -.

- Remove bolt - 1 -.





- Disconnect the ATF pipe from the ATF filter and remove the clip - arrow -.

• Disregard - 2 -.

- Tie the ATF pipes - 1 - and - 2 - upward.





• Disregard - 3 -.

- Seal any open lines and connections with a clean plug from the Engine Plug Set (VAS 6122).

- Remove bolts - 2 through 5 - connecting the engine to transmission. They are accessible from above.





• Ignore - A -.

- Position Engine Support Bridge (10 - 222 A) with Connector (10 - 222 A /1) on the left and right suspension strut towers as shown in the illustration.





- Engage Spindle (10 - 222 A /11) in the left engine lifting eye.

- Slightly pretension the engine with the spindle.

- Remove the bolts - arrows - and the right drive axle heat shield.





- Remove left and right drive axles from transmission flange shafts.

- Press selector lever cable ball socket - 2 - off the selector shaft lever using the Pry Lever - Rmv Outside Mirror (80 - 200).





- Remove circlip - 1 - and free up the selector lever cable.

• Do not bend or kink the selector lever cable.

CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

• Always discharge "static electricity". Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.

• Do not touch contacts in transmission connector with hands.

- Disconnect electrical connector on transmission by rotating screw connections counterclockwise - arrow -.





- Disconnect the connector- 2 - on the Engine Speed Sensor (G28) and free up the wire on the transmission.





• Disregard - 1 -.

CAUTION!
The airbag spiral spring could be damaged.

• Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.

• Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.

- Remove the universal joint bolt - arrow -. Refer to => Suspension, Wheels, Steering 48 Description and Operation.





- Press universal joint off the steering gear and slide it all the way up.

- Remove the nut - 1 - for the power steering hydraulic oil line.





CAUTION!
The suspension components could be damaged.

• Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

- Remove the bolts - arrows - and the subframe crossbrace.

- Remove the bolts - arrows - and the driveshaft heat shield - 1 -, where applicable.





- Remove the bolts that connect the driveshaft to the transmission by counterholding them with the Counterholder (T10172) and (T10172/5).





- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

- Secure the driveshaft to the side.

- Remove the cover - 1 - from the bottom of the transmission - arrow -.





- Insert the Adapter (T40058) guide pins as follows:





• The larger diameter - arrow 1 - faces toward the engine.

• The small diameter - arrow 2 - faces toward the adapter.

- Counterhold the crankshaft using the Adapter (T40058) to loosen the drive plate bolts.





• When mounting, turn the crankshaft only in the direction of engine rotation - arrow -.

- Remove the 6 drive plate bolts - arrow - while turning the crankshaft 60° further in the direction of engine rotation.





- Place the Oil Collecting and Extracting Device (V.A.G 1782) at the separating joint.

- Remove bolts - arrows -, disconnect the hydraulic oil line - 1 - from the steering gear and lay it to the side.





- Seal any open lines and connections with a clean plug from the Engine Plug Set (VAS 6122).

- Remove the starter bolt - 1 -.





- Remove the starter from the transmission and leave it in the installation position.

- Remove remaining transmission to engine connecting bolts - 6 through 10 -.

• Ignore - A -.

CAUTION!
Danger of leaks in the ATF oil pan.

• The Transmission Support (T40173) must not be set on the ATF oil pan.

- Place Engine/Transmission Jack (V.A.G 1383 A) with the Transmission Support (T40173) under the transmission.

The transmission support must be placed at the front as follows:

• The bracket - 2 - fits into the dual-mass flywheel on the transmission housing on the left side of the transmission.





• The transmission support is installed with an elastic washer - 1 - on the center differential housing on the right side of the transmission.

- Secure the transmission with the tensioning belt - 1 -.





- Remove tunnel crossmember bolts - arrows -.





• The Engine/Transmission Jack (V.A.G 1383 A) is not shown i the illustration.

- Press the transmission off the engine and lower it carefully using the Engine/Transmission Jack (V.A.G 1383 A).