5 Speed Automatic 09A
Transmission, removing and installing
Special tools and equipment
- 10-222 A Support
- 10-222 A/2 Auxiliary hooks
- 10-222 A/3 Adapter
- 10-222 A/8 Adapter
- 10-222 A/12 Shackles
- 3094 Hose clamps
Special tools and equipment
- 3282 Transmission support
- 3300 A Engine support
- T10036 Support rails
- V.A.G 1331 Torque wrench
- V.A.G 1332 Torque wrench
- V.A.G 1383A Engine/transmission jack
Special tools and equipment
- 3282/26 Adjustment plate
- V/175 Socket
- T10099 Multi-point bit, 12 mm
- T10099/1 Multi-point bit, 14 mm
Removing
- Check whether a coded radio is fitted. If so, obtain anti-theft coding.
- Remove cover from engine.
- Switch ignition off and disconnect battery Ground strap.
- Install battery.
- Remove battery carrier.
- Remove intake hose -1-, connector -2- and hose -3- from mass air flow sensor.
- Remove complete air cleaner housing by removing bolts -4- and -5-.
- Remove intake hose -1
- Remove retainer -arrow- from transmission.
- Shift selector lever in "P" and lever selector lever cable -1- off lever/selector shaft -4- using a screwdriver.
- Do not loosen bolt -2-.
- Remove circlip -3- at selector lever cable support bracket and remove selector lever cable.
Note: Do not kink selector lever cable.
- -Pull connector -1- off wire for multi-function switch.
- Turn locking lever-2- and unplug connector for transmission wiring harness.
- Disconnect electrical connections on starter.
- Remove starter -3-.
- Clamp-off ATF cooler hoses with tool 3094 and detach at ATF cooler.
- Seal off ATF cooler with clean plugs.
- Remove upper engine/transmission securing bolts using multi-point bit T10099/1.
- Disconnect fuel line/hose from cylinder head cover.
- Check for hose and cable connections in area of engine mounting eye for support 10222A and remove if necessary.
- Fit support bar 10-222A in conjunction with adapters 10-222 A/3 and 10-222 A/8.
- Take weight of engine/transmission assembly on spindles.
- Remove front left wheel bolts.
- Raise vehicle.
- Remove left wheel.
- Remove sound insulation tray -arrows-.
- Remove left sound insulation -arrows-.
- Remove pipe between charge air cooler and turbocharger from longitudinal member.
- Remove right sound insulation.
- Remove front exhaust system with catalyst.
- Remove Ground strap -1- from retainer on transmission.
- Remove power steering line -2- from front of transmission (arrows).
- Remove retainer -3-.
- Remove power steering line from rear of transmission (in area of pendulum support) and tie to one side.
- Remove retaining bracket from valve body cover.
- Disconnect drive shafts at transmission flanges.
- Raise right drive shaft and secure.
- Remove lower rear engine/transmission securing bolt-A-.
- Unclip cap for torque converter nuts cover.
- Remove nut (arrow) from torque converter (Qty. 3) using socket V 175.
Turn crankshaft 120° further in each case.
- Loosen retainer -B- for oil level/temperature sender cable and turn to side.
- Turn steering to left lock.
- Mark installation position of ball joint bolts on lefthand control arm and remove bolts.
- Remove bolts (arrows).
- Disconnect left connecting link -1- from control arm and turn link upward.
- Swing wheel bearing housing outward.
- Guide left drive shaft -2- out between sub-frame and transmission.
- Lift drive shaft and secure to suspension strut with wire.
- Remove lower engine/transmission bolts -2- and -3-.
- Remove Ground strap retainer -1- from transmission.
Note: Do not yet remove bolt -4-.
- Remove pendulum support.
- Remove left assembly mounting -2- hex bolts -arrows- from left console -1-.
- Carefully tilt engine and transmission by lowering both spindles approx. 90 mm on support bar 10-222 A.
- Turn right-hand flange shaft -B- with flat in vertical position.
- Bolt support rail T10036 at two pendulum support securing holes on subframe (bolts -A) and tighten.
- Install support 3300 A so that it is almost touching assembly mounting and secure (arrows).
- Press engine/transmission forward carefully.
Note: Do not damage any of the connecting lines and hoses when moving engine/ transmission assembly.
- Set up transmission support 3282 with adjustment plate 3282/32 to remove 5-speed automatic transmission 09A.
- Align arms of transmission support according to holes in adjustment plate.
- Bolt on support elements -A-, as illustrated, on adjustment plate.
- Place transmission jack under vehicle, on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission.
- Secure transmission to transmission support 3282 with bolt -A-.
- Remove engine/transmission connecting bolt (arrow).
- Separate transmission from engine and press torque converter out of drive plate.
- Press torque converter against ATF pump -arrow-.
- Carefully swing transmission towards subframe.
- Lower transmission carefully, guiding right-hand flange shaft -A- in area of drive plate and left-hand flange shaft -B- past subframe.
- When lowering transmission change position of transmission using the transmission support 3282 spindles.
- Secure torque converter to prevent it falling out.
- If transmission is to be replaced, remove old transmission mount -A- -arrows- and install on new transmission.
Transporting the automatic transmission
For transportation of the automatic transmission and setting up the transmission support 3282, shackle 10-222 A/12 in conjunction with auxiliary hook 10222 A/2 can be used.
- Secure shackle 10-222 A/12 to transmission housing.
Installing transmission
Install in reverse order but note following:
- Install torque converter.
The torque converter is correctly installed when the distance -a- between the flange on the transmission housing and the contact surface of the torque converter locating pins is:
- 21 mm on 4-cylinder engines
- 17 mm on 6-cylinder engines.
Note: It is essential that the distance -a- be adhered to for the rest of the installation. The torque converter must not slip forward.
- If transmission is to be replaced, remove old transmission mount -A- -arrows- and install on new transmission.
- Ensure that dowel sleeves are correctly located.
- Observe torque converter contact impression on drive plate.
- Replace selector cable anchorage locking washer.
- Check selector lever cable adjustment, adjust if necessary.
- Check and top up ATF level.
- Perform On Board Diagnostic (OBD) and initiate basic setting.
- Enter radio code.
Tightening Sequence
Tightening Torques
Transmission to engine
Items A + B - Fitting sleeves
Transmission to body
- Replace bolts
Bolts -arrows- 50 Nm + 90°
Rear transmission mounting
- Replace bolts
Bolts -A- 20 Nm + 90°
Bolts -B- 40 Nm + 90°
Note: Install engine/transmission mountings stress free.
Transmission console -A- to transmission
- Replace bolts
Bolts -arrows- 50 Nm
Torque converter to drive plate 60 Nm