Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Ring Spanner Insert AF 16 (V.A.G 1332/14)
• Engine/Transmission Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Puller for Gear Shaft Linkage (T40160)
• Transmission Support (T40173)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Socket (T40058)
• Engine Support Supplement Set (T40093)
• Release Tool f/ Rev. Light Switch Conn. (T40138)
• Jointed Socket, 12 mm (T40220)
• Extractor (T40176)
• Engine Bung Set (VAS 6122)
• Used Oil Collection and Extraction Device (V.A.G 1782)
• Bolt M8 x 35 and washer outside dia. 25 mm
Removing
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Position the front wheels so they are straight.
- Turn off the ignition and remove the key.
- Disconnect the ground (GND) cable - 2 - from the battery terminal.
- Remove the engine covers - 1 - and - 2 - upward - arrows -.
- Position the (10 - 222 A) with the (T40093/6) on the left and right suspension strut towers as illustrated.
- Secure the spindles (10 - 222 A /11) in the left and right engine lifting eyes.
- Tension the engine slightly using the spindles.
- Remove the left and right front wheels.
- Remove the left and right noise insulation - 1 - inside the wheel housing.
- Remove the noise insulation by loosening the fasteners - 1 through 3 -.
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 nut - 1 - from the power steering hydraulic line.
- Remove the bolts - arrows - and remove the subframe crossbrace.
• The illustration shows the installed position in a vehicle with dynamic steering.
- Remove right and left subframe shield - 1 -. Do this by removing the bolts - arrows - and then removing the shield toward the inside.
- Remove the nuts - arrows - for the left front muffler.
- Remove the nuts - arrows - for the right front muffler.
Danger of damaging the flex joint in the front muffler.
• Do not bend the decoupling element in the front muffler more than 10°.
- Loosen the clamping sleeves - 1 - and - 2 -, push toward the rear, and remove the left and right front muffler.
- Remove the bolts - arrows -, and remove the driveshaft heat shield - A - (if equipped).
Driveshaft Bolted on the Transmission Side:
- Remove the bolts that connect the driveshaft to the transmission by counterholding them with the (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.
Driveshaft Mounted on the Transmission Side:
- Remove the driveshaft.
For All Vehicles
- Disconnect the connector - 2 - from the engine speed sensor (G28) and free up the wire.
• Ignore - 1 -.
- Remove the lower cover - 1 - from the transmission - arrow -.
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
- Counterhold the crankshaft with the (T40058) and an angled box wrench to loosen the torque converter bolts for the clutch module at the drive plate.
• When mounting, turn the crankshaft only in the direction of engine rotation - arrow -.
- Turn the clutch module over both front wheels 60° in direction of engine rotation and remove the six drive plate bolts - arrow - for the clutch module on the drive plate.
- Remove the engine/transmission connecting bolts - 7 to 11 -.
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 -.
- Press the universal joint off the steering gear and slide it all the way up.
- Place the (V.A.G 1782) under the hydraulic oil line's separating point - 1 - on the steering gear.
- Remove the bolts - arrows -, disconnect the hydraulic oil line - 1 - from the steering gear and move it to the side.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
- Remove the bolt - 1 - press the retaining tab off the transmission and tilt it back - arrow -.
- Remove the bolt - 2 - and secure the clutch slave cylinder sideways in the engine compartment.
The clutch slave cylinder could be damaged.
• Do not activate the clutch pedal after the clutch slave cylinder has been removed.
- Remove the selector rod 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.
- Install the (T40160) and remove the transmission shift lever - 1 -.
- 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 bolts - arrows - from the tunnel crossmember.
- Lower the transmission using the (V.A.G 1383 A) first to dimension - a -.
• Dimension - a - = maximum 100 mm.
- Tension the (10 - 222 A) spindles (10 - 222 A /11) slightly.
• Use the (VAS 5085) to get to (10 - 222 A /11) on the hoisted vehicle.
- Remove the electrical connector - 1 - on the transmission range gear recognition switch (F208) using the (T40138).
- Remove the push rod bolt - 2 -.
- Remove the connecting rod bolt - 3 -.
- Remove the bolts - arrows - and remove the heat shield from the right drive axle.
• 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 the left and right drive axles from the transmission flange shafts - arrows -.
- Remove the nuts - arrows - and the bolt - 1 -, and push the right catalytic converter to the right side and secure.
• The illustration shows the installation position with the engine removed.
• Use the (T40220) to loosen the nuts - arrow -, right catalytic converter - A - on the exhaust manifold.
• Secure the right catalytic converter loosely using a nut so it does not fall down.
- Remove the bolt - 1 - from the starter.
- Remove the bolt - 4 - and leave the starter in the installed position.
• Ignore - 2 through 3 -.
- Remove the remaining bolts - 3 through 6 - that attach the engine to the transmission.
- 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:
• Right and left bracket - 1 - for the exhaust system.
• 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.
• Remove the clutch module if necessary.
