Replacement

Transmission, Removing and Installing Passat 096 Transmission








Removing

- Obtain radio code on vehicles with coded radio.

- Disconnect battery Ground (GND) strap.
- Remove battery on vehicles with 6-cylinder engines.

- Disconnect speedometer connector at transmission.

- Remove electrical connections (arrows) at transmission.

- Move selector lever to "P" and disconnect selector lever cable from lever/selector shaft.

- Remove selector lever cable anchor circlip and remove selector lever cable.









- Clamp-off ATF cooler hoses with 3094 or equivalent and disconnect hoses at ATF cooler.

- Disconnect harness connector for Coolant Fan

- Remove upper engine/transmission mount bolt

- Remove Starter.






- Install support bar 10-222 A with legs 10-222 A/1 (6 cyl engine adapter 10-222 A/3) and support engine/transmission in this position.







- Remove vacuum line -a- and connector -b- before installing support bar into eye (arrow) on vehicles with 6-cylinder engines.






- Disconnect front mount bracket from engine carrier

- Remove mount bracket

- Remove coolant expansion tank and set aside

- Remove left engine mount complete.
- On vehicles with 6-cylinder engine remove drive belt cover.

- Disconnect axle shafts at transmission drive flanges

- Remove left wheel.







- Turn steering to right lock.

- Raise right axle shaft and secure.

- Mark installation position of ball joint bolts on left side control arm and remove bolts.

- Vehicles with Plus suspension, remove bolts -A- and loosen bolts -B-.

- Swing ball joint outward and place left side axle shaft to one side.

- Vehicles with tripodic (star-shaped) joint: remove drive shaft.







- Disconnect harness connector from Multi-function Transmission Range (TR) Switch and remove switch.

- Remove ATF oil pan protective plate.







- Remove balance weight.

- Remove bracket for power steering pressure hose.

- Remove torque converter cover plate and remove nuts from torque converter.

- Tilt engine and transmission forward with supporting device 3300 A.






- Lower engine using support device spindle.

- Set up gearbox mount 3282.

Transmission mount 3282 is set up with the adjusting plate 3282/2 for removing the automatic transmission 096.
The symbols on the adjusting plate indicate the mounts required.






- Move jack VAG 1383 A with transmission support 3282 under transmission and support.






- Place securing mount pin on transmission pan and secure to housing (arrow).

- Remove lower engine/transmission connecting bolts

- Pry transmission off engine; when doing this, press torque converter out of drive plate

- Press torque converter against ATF pump. Lower transmission slightly.

- Tilt transmission using jack spindle and while lowering ensure cover (wheelhousing side) is guided closely past wheelhousing.

- Rotate transmission and lower it carefully.

- Secure torque converter to prevent it falling out.

Installing

Installation is carried out in the reverse order. When installing the torque converter, ensure that both drive pins engage in the ATF pump inner wheel recesses.

Before installing, ensure that dowel sleeves for aligning the engine and transmission are correctly located. Replace selector cable anchor locking washer.

Check selector lever cable adjustment



Tightening torques
Axle shaft to drive flange 45 Nm (33 ft lb)
Torque converter to drive plate 60 Nm (44 ft lb)
Transmission to engine:
Bolt M12 80 Nm (59 ft lb)
Bolt M10 60 Nm (44 ft lb)
Front mount to mounting assembly 60 Nm (44 ft lb)
Left mount to mounting assembly 60 Nm (44 ft lb)
Left mount to transmission 25 Nm (18 ft lb)
Cover plate to transmission 15 Nm (11 ft lb)
Ball joint to control arm 35 Nm (26 ft lb)
Starter to transmission 60 Nm (44 ft lb)