Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Bracket with Spindle and Hook (10 - 222 A /10)
• Shackle (1 Set=2 Pieces) (10 - 222 A /12)
• Bracket (T10338)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Hose Clamps Up to 25 mm Dia. (3094)
• Transmission Support (3282)
• Pin (3282/29)
• Adjusting Plate (3282/42 A)
• Engine/Transmission Jack (V.A.G 1383 A)
• Engine Bung Set (VAS 6122)
Procedure
• General repair instructions, refer to => [ Repair Information ] 02EA (S-Tronic) Transmission.
• Observe cleanliness rules when working on transmissions, refer to => [ Clean Working Conditions ] 02EA (S-Tronic) Transmission.
• Refer to the information on the S-Tronic transmission 02E, refer to => [ Transmission ] Transmission.
• Reinstall cable ties that were loosened or cut off during removal at the same locations during installation.
- Move the selector lever into "P".
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Turn off the ignition and disconnect the Ground (GND) cable from the battery.
- Remove the air filter housing.
- Remove the bolts - arrows - and remove the air filter housing bracket.
Selector Mechanism through 11.09:
- Remove the locking plate - C -.
- Push the lock washer - A - upward and remove it.
- Remove the selector lever cable from the transmission selector lever - arrow - pull it out of the bracket - D -.
• The selector lever cable must not be bent or kinked.
• Ignore - 1 and B -.
Selector Mechanism from 11.09:
- Remove the bolts - 1 - from the bracket.
- Remove the lock washer - 3 - - arrow - and then remove the selector lever cable from the transmission.
• Ignore - 2 -.
All Vehicles:
- Cut the cable tie - arrow - from the boot.
- Disconnect the connector - 2 -.
- Fold back the protective boot - 1 - and disconnect the battery positive cable from the starter solenoid switch.
- Disconnect the Ground (GND) wire - 3 -.
There is a risk of destroying the control module (Mechatronic) with electrostatic discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge electrostatic, touch vehicle ground with hand (without glove).
- Disconnect the connector - 4 - on the transmission by turning screw connection counterclockwise.
- Clamp off coolant hoses on transmission oil cooler with the (3094) and remove from cooler - A -.
• To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.
- Remove all the bolts in the transmission to engine connection that are accessible from above.
• The bolt - 3 - is located in the opening for the starter.
- Install the (T10338) on the open threaded hole at left rear of the engine.
- Position (10 - 222 A) with the following tool components on the upper edges of engine compartment:
• (10 - 222 A /1) , quantity: 2
• (10 - 222 A /10) (spindle faces toward rear)
• Spindle (10 - 222 A /11) (spindle faces toward front)
• (10 - 222 A /12)
• Connectors (T40091/3) , quantity. 2
- Attach the spindle (10 - 222 A /11) and (10 - 222 A /12) to the right engine lifting eye.
- Engage (10 - 222 A /10) on (T10338).
- Lightly tension the engine/transmission assembly with spindles.
- Install the left adapter (T40093/3-2) and (T40093/3-3) and right adapter (T40093/3).
- Remove the GND wire from left longitudinal member.
- Remove the left and right connecting bolt for the front part of long member.
- Install the adapters on longitudinal members with the bolts that were removed earlier - arrow -.
• The left side of the vehicle is shown in the illustration.
- Insert the square tubes (T40091/1) into the connector (T40091/3) and supports (T40093/3) , as illustrated.
- Slide the connector (T40093/4) onto the square tube.
- Slide the support (T40091/2) with the (T40093/5) into both connections (T40093/4).
Risk of an accident due to loose support bridge parts.
• Secure the engine support supplement set (T40091/2) with the bolts and splints from the (T40093/4).
• Secure the connector and supports with locking bolts.
- Install the (10 - 222 A /11) on the slide and engine lifting eye.
- Tension the engine/transmission assembly by tightening the 3 spindles evenly.
- Remove both front wheels.
- Remove the front noise insulation - 1 -.
- Remove the left and right front wheel spoilers.
- Remove the frame for the noise insulation - arrow -.
Danger of damaging the sealing ring in the driveshaft flange.
• When loosening the pedal support/subframe bolts, engine/transmission assembly moves forward slightly.
- Remove the bolts - 1, 2 and 3 - and remove the pendulum support.
- Disconnect the connector - 1 - on the oil level thermal sensor (G266).
- Remove the bracket - 2 - for the oil level thermal sensor wire from the subframe.
- In order to avoid a vehicle alignment, secure the subframe.
- Remove the subframe.
- Remove the right drive axle heat shield from bevel box.
- Remove the left drive axle from transmission flange.
- Remove right drive axle from the bevel box flange.
- Lift the drive axles and secure them with cable ties.
• Make sure drive axle protective coating is not damaged.
- Remove the bolts - 1 and 2 - and the bevel box mount - A -.
- Remove the secondary air pump.
- Free up the electric wires on the front of the transmission - arrows -.
- Identify position of flexible disc and bevel box flange to each other.
- Remove driveshaft flexible disc from bevel box - arrows - while counter holding at triangular flange with a lever.
Risk of damaging sealing ring - arrow - in driveshaft flange.
• Press driveshaft horizontally as far back and to the right side of the vehicle as possible.
• If seal is damaged, driveshaft must be replaced.
- Tie driveshaft up.
- Remove the bolts - 1 and 2 - and the transmission support - A -.
- Lower the engine/transmission sub-assembly by the spindle on the (10 - 222 A) until dimension - a - is reached between the transmission housing and the transmission mount.
• Dimension - a - = 100 to 110 mm.
To remove the (3282) , the transmission support is equipped with the (3282/42 A) and positioned on the (V.A.G 1383 A).
- Align the arms of the transmission support to correspond with the holes in the (3282/42 A).
- Install the support elements on the (3282/42 A) as shown. The "retaining plate with hole" is used as a front support element.
- Place the (V.A.G 1383 A) under the vehicle.
• The arrow symbol on the adjustment plate points in the direction of travel.
- Align the (3282) so that it is parallel to the transmission.
- Screw the (3282/29) into the transmission.
- Attach the "retaining plate with hole" securely to the transmission - arrow - as shown.
- Insert the last support element in the transmission as shown.
- Support the transmission by lifting it from underneath using the (V.A.G 1383 A).
- Remove the remaining bolts from transmission to engine connection.
- Remove the transmission from the alignment sleeves.
- Remove the transmission from engine at bevel box side and then at front side.
- Carefully lower the transmission using the (V.A.G 1383 A). Be careful not to get any lines caught.
- When lowering, change position of transmission with spindles on (3282).