Removing and installing

Note:
Before attempting to repair the automatic transmission, first read Diagnostic Trouble Codes (DTC) using VAG 7551 Scan Tool (Refer to Transmission Control Systems; Testing and Inspection). Then identify and locate the fault before starting to repair.

Required special tools and equipment:








^ 10-222 A Support bar
^ 3094 Hose clamps
^ 3282 Transmission support
^ 3282/2 Adjustment plate
^ 3300 A Engine support
^ 3336 Transmission lifting beam
^ WV 457/1 Support rails
^ 10-222 A/8 Adapter
^ V.A.G 1331 Torque wrench or similar
^ V.A.G 1332 Torque wrench or similar
^ V.A.G 1383 A Engine/transmission jack
^ V1175 Socket

Support rails VW 457/1, modifying





To install support rail VW 457/1 to the subframe, a new hole is required.
^ Dill hole 8.5 mm (1/32 inch) diameter -arrow- in support rail VW 4,157/1.
^ Measurements are in mm

Guide bar 10-222 A/21 of transmission support 10-222 A, modifying
To support engine and transmission you need support 10-222 A.





To install adapter 10-222 A/8 to guide bar 10-222 A/21, an additional hole is required.
^ Drill hole 12.5 mm (4.9 inch) -arrow- in guide bar 10-222 A/21.
^ Measurements are in mm

Removing:

CAUTION!
^ Before working on the electrical system, obtain radio security code and disconnect battery Ground (GND) strap.
^ When reconnecting battery, always check operation of vehicle equipment.
^ Remove engine cover.
^ Remove power steering fluid reservoir from battery support. Do not disconnect lines.
^ Suspend reservoir at lock carrier.
^ Remove battery.
^ Remove battery support bracket.





^ Remove air intake hose -1- and connector -2- from Mass Air Flow (MAF) Sensor.
^ Remove bolts -3- and -4-.
^ Remove air cleaner as complete unit.
^ Remove connector from vehicle speed sensor.





^ Remove electrical connections -1- to -4- at transmission.
1 To solenoid valves
2 To Vehicle Speed Sensor -G38-
3 To Multi Function Transmission Range (TR) Switch -F125-
4 On Transmission Vehicle Speed Sensor -G38-
^ Remove wiring harness from retainer on transmission and move to the side.
^ Remove bracket for power steering hose with retainer for wiring harness from transmission.





^ Move selector lever to " P" Using a screwdriver, pry off selector lever cable -1- off lever/selector shaft -4-.
^ Remove clip -3- at selector lever cable support bracket and remove selector lever cable.
^ Do not kink selector lever cable.

Vehicles with 2.0L engine





^ Remove Vehicle Speed Sensor -1-.
^ Remove bolt -2-.
^ Remove heat shield -3- for exhaust manifold from engine.

All vehicles:





^ Disconnect ground cable -1- from upper engine/transmission bolt.
^ Disconnect electrical connections -3- and -4- at starter motor.
^ Disconnect connector -2- and pull out of retainer.
^ Remove wiring harness retainer at starter motor.
^ Remove upper starter motor bolt.





^ Clamp-off ATF cooler hoses with tool 3094 and detach at ATF cooler.
^ Seal ATF cooler with clean plugs.
^ Remove upper engine/transmission bolts.





^ Install support bar 10-222 A with legs 10-222 A/1 and support engine and transmission in this position.
Do not support adapter 10-222 A/8 on tender bolts.
^ Slightly lift engine/transmission assembly with spindles.
^ Loosen left front road wheel bolts.
^ Lift vehicle.
^ Remove left road wheel.





^ Remove center noise insulation panel -arrows-.





^ Remove left noise insulation panel -arrows-.

Vehicles with TDI engine:
^ Remove intake air duct between intake air cooler and turbo charger

All vehicles:
^ Remove right noise insulation panel.





^ Remove ATF pan protective cover -arrows-.
^ Remove power steering pressure line from starter motor and transmission.
^ Remove lower starter motor bolt.
^ Remove starter motor.
^ Remove protective cover from engine for right inner constant velocity joint if equipped.
^ Disconnect drive shafts at transmission flanges.
^ Lift right drive shaft and secure with wire.





^ Remove pendulum support -arrows-.
^ Remove auxiliary fan on right vehicle side if equipped.
^ Remove cap for torque converter nut cover.





^ Remove torque converter nuts (Qty. 3) -arrow- with special tool V175.
Turn crankshaft 120° for each nut.
^ Turn steering to left lock.
^ Mark installation position of axle joint bolts on left control arm.





^ Remove bolts -arrows-.





^ Remove left coupling rod -1- from control arm and turn coupling rod 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.
^ Disconnect exhaust at front double clamp. Remove front exhaust support if necessary.





^ Remove bolts -arrows- of left engine/transmission mount -2- from the left support -1-.
^ Carefully tilt engine and transmission by lowering left spindle of support bar 10-222 by approx. 60 mm (2.3 inch) .





^ Remove left support -1- from transmission -arrows-.





^ Install support rail VW457/1 to both pendulum support bolt holes on subframe.
^ Insert spacers totaling 6 mm (2.3 inch) between subframe and support rail VW 457/1.
A Bolts M8 x 25 (qty. 2)
^ Install support device 3300 A and tighten with bolt -B-.
^ Tilt engine/transmission forward with support 3300 A.





^ Assemble Transmission support 3282.
The Transmission support 3282 must be installed with adjusting plate 3282/2 to remove the transmission.
The markings on the adjusting plate indicate the required supports





^ Move jack VAG 1383 A with 3282 under the transmission and support it.





^ Place safety support pin on oil pan and secure it to transmission housing (arrow).





^ Turn transmission flange to the right until flat -arrow- is vertical.
^ Remove lower engine/transmission connecting bolts.
^ Separate transmission from engine while pushing torque converter out of drive plate.
^ Push torque converter against ATF pump.
^ Lower transmission slightly.
^ While lowering transmission, guide power steering pressure line past transmission,
^ Turn transmission and carefully lower.
^ While lowering transmission, guide right axle joint at engine past support 3300 A .
^ Be careful not to let multi-function switch contact engine/transmission mount.
^ Secure torque converter to prevent it from falling out.

Installing:
Install transmission in reverse order of removal.
When installing torque converter, be sure that both drive pins engage in the ATF pump inner wheel recesses.
^ Before installing, be sure that the dowel sleeves are correctly located.
^ When installing transmission, check torque converter contact pattern on drive plate.
^ Replace selector cable anchor lock clip.
^ Check selector lever cable adjustment, adjust if necessary.
^ Check and top up ATF level.
^ Connect VAG 1551 and check Diagnostic Trouble Code (DTC) memory.

Tightening torques:
Drive shaft to flange 40 Nm (30 ft. lbs.)
Torque converter to drive plate 60 Nm (44 ft. lbs.)
Transmission to engine bolt M12 80 Nm (59 ft. lbs.)
Transmission to oil pan/engine M10 45 Nm (33 ft. lbs.)
Axle joint to control arm 20 Nm (15 ft. lbs.) +90°
Coupling rod to control arm 45 Nm 33 ft. lbs.)
Wheel bolts to wheel hub 120 Nm (89 ft. lbs.)
Protective cap to drive shaft at engine 33 Nm (24 ft. lbs.)





Transmission to body
Bolts -A- 60 Nm (44 ft. lbs.) + 90°
Bolts -B- 40 Nm (30 ft. lbs.) + 90°
- Always replace bolts





Rear Transmission mount
Bolts -A- 20 Nm (15 ft IN + 90°
Bolts -B- 40 Nm (30 ft. lbs.)+ 90°
- Always replace bolts

Note:
Install engine/transmission mounts stress-free.

Automatic transmission, transporting
Use special tool 3336 to transport the automatic transmission and also when installing transmission support 3282.





^ Attach special tool 3336 to transmission housing flange.
^ Position pins that 8 holes are visible in chain direction.