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)

• 2 x Hose Clamps Up to 25 mm in Dia. (3094)

• Hose Clip Pliers (V.A.G 1921)

Removing






- Turn off the ignition and remove the key.

- Disconnect the battery.


Risk of damaging electronic components when disconnecting the battery.

• Follow the steps when disconnecting the battery.

- Carefully remove the engine cover from the pins in the direction of the - arrow -. Do not pull sharply on the engine cover or pull it to one side.






- Position the (10 - 222 A) with the (10 - 222 A /3) on the left and right suspension strut towers as illustrated.






- Engage the (10 - 222 A /11) on the engine lifting eyes.

- Loosen the fasteners - 1 through 4 - and - arrows - 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 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.

Vehicles with Transmission Fluid Heater






- Remove both of the coolant hoses from the transmission with (3094).

- Place the drip tray underneath the transmission, open the spring clamps - 1 - and remove both of the coolant hoses.

All Vehicles






• Do not bend the flex joint in the front exhaust pipe more than 10° or it will be damaged.

- Disconnect exhaust system at the double clamp - arrow -.

- Secure the front exhaust pipe on the heat shield under the shift mechanism with wire.

- Remove the bolt - 1 - and tilt the catalytic converter bracket to the right.






• Ignore the nuts - arrows -.

- 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 120° in direction of engine rotation and remove the three 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 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 inward to remove the subframe shield - 1 - on the left and right.

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






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






- Disconnect the connector from the transmission neutral position sensor (G701) - 1 - and free up the cable.






- 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 engine/transmission connecting bolts - 8 to 11 -.






• The bolts - 1 through 7 - connecting the engine to the transmission are removed and installed from below with the transmission lowered.

- Position the (V.A.G 1383 A) and the (T40173) under the transmission and secure it with the tensioning strap - 1 - as illustrated.






• Be careful not to get the electrical wires caught on the transmission when attaching the tensioning strap.

- 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 80 mm.

- Slightly pretension the threaded spindles on the (10 - 222 A).

• Use a (VAS 5085) to get to the threaded spindles when the vehicle is raised.

- Disconnect the connector - 1 - from the transmission range gear recognition switch (F208) or the gear recognition sensor (G604) with the release tool (T40138) and free up the wires.






- Remove the push rod bolt - 2 -.

- Remove the connecting rod bolt - 3 -.

- Remove the starter bolt - 3 - from the engine side.






- Remove the bolt - 1 -.

- Remove the spacer sleeve - 2 - between the starter and the transmission.

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

• It is not necessary to disconnect the starter cable.

- Remove all remaining engine/transmission bolts.

- 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:






• Bracket - 1 - for the exhaust system straps.

• 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.

• Removing the clutch module if necessary.