3.0 TDI
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A) for vehicles with all wheel drive
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Engine Bung Set (VAS 6122)
• Tensioning Strap (T10038) for vehicles with all wheel drive
• Socket (T40058)
• Engine Support Basic Set (T40091) for vehicles with all wheel drive
• Engine Support Supplement Set (T40093) with (T40093/7) , (T40093/8) for vehicles with all wheel drive
• Transmission Support (T40173)
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 up as illustrated.
Removing
- Position the front wheels so they are straight.
Risk of damaging electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the battery.
- Remove the engine cover - arrows -.
- Remove the noise insulation - 1 and 2 -.
• Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive repair information.
- Remove the driveshaft.
- Remove the ATF cooler. Refer to => [ ATF Cooler ] Service and Repair.
- Remove the particulate filter.
- Remove the bolts - 2 through 5 - connecting the engine to transmission. They are accessible from above.
- Position the (10 - 222 A) with (T40091/4) , (T40091/5) , (T40093/7) and (T40093/8) on the left and right suspension strut towers as illustrated.
- Attach the spindle (10 - 222 A /11) the left rear engine lifting eye and slightly tension the engine.
- Attach the (T10038) to the right front engine lifting eye and to the (10 - 222 A) as illustrated.
• Catch any leaking ATF with a cloth.
- Remove the bolts - arrows - and remove the ATF pipe - 1 - from the transmission.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge static electricity, touch the transmission housing (without wearing gloves).
- Disconnect the connector on transmission by rotating screw connections counter-clockwise - arrow -.
- Free up the electrical wiring harness on the transmission.
- Loosen the clamp - arrow - and remove the coolant hose.
- Remove the bolts - arrows - and then remove the heat shield from the right drive axle.
- Remove the bolts - arrows - and the left drive axle heat shield.
- Remove the left and right drive axles from the transmission flange shafts.
- Remove the steering intermediate shaft from the steering gear and push it upward.
- Disconnect the connectors - 2 - from the Engine Speed (RPM) sensor (G28) and free up the wire.
• Ignore - 1 -.
- Release the retainers - arrows A - and slide the sleeve - 1 - in direction of - arrow B -.
- Disconnect the rear emergency release cable from the front emergency release cable - arrow C -.
- 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.
- Counter hold the torque converter by the crankshaft drive plate using the (T40058) when loosening the bolt.
• When mounting, turn the crankshaft only in the direction of engine rotation - arrow -.
- Remove the six torque converter bolts - arrow - while turning the crankshaft 60° further in the direction of engine rotation.
- Remove the bolt - 1 - from the starter.
- Remove the starter from the transmission and leave it in the installation position.
- Remove the remaining engine/transmission bolts - 6 through 11 - but leave one bolt - 7 - installed hand-tight.
Danger of leaks in the ATF pan.
• The (T40173) must not be set on the ATF pan.
- Place the (V.A.G 1383 A) with the (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 mount is positioned on the differential housing on the right side of the transmission. Insert a flat piece of rubber - 1 - in between to protect the housing.
- Secure the transmission with a tensioning strap - 1 -.
• The (T40173) is not illustrated.
- Remove the bolts from the tunnel crossmember - arrows -.
- Remove the last bolt from the transmission to engine connection.
- Press the transmission off the engine and lower it carefully using the (V.A.G 1383 A).