Removing and Installing

Transmission, removing and installing (vehicles with V6 engine)
Special tools, workshop equipment, test and measuring appliances and aux. items required

- 10-222A Support
- 10-222 A/1 Support
- 10-222 A/3 Adapter
- 10-222 A/12 Shackles
- 80-200 Removal lever
- 3282 Transmission support

- 3282/19 Adjustment plate
- 3393 Test mandrel
- 3457 Transport device
- VAG 1306 Drip tray
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench

- VAG 1383A Engine/transmission jack

- VAS 5085 Step-ladder

Removing
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground strap.

- Unscrew bolts -arrows- and remove engine cover.
- Take intake hose off intake manifold.
- Fit support bar 1 0-222A together with legs 10-222 A/1 and adapters 10-222 A/3
- Secure spindles to engine. In addition, use a shackle 10-222 A/12 on the front of the engine to avoid damage.
- Take weight of engine/transmission assembly on the spindles.
- Loosen wheel bolts.
- Raise vehicle.
- Remove front wheels.

- Remove noise insulation tray -arrows-.

- Remove front exhaust system with catalyst.

- Remove protective plates for left and right hand drive axles -arrows-. The third bolt cannot be seen in the illustration.
- Disconnect left and right-hand drive axles -1- from flanges and tie-up.

- Remove noise insulation tray bracket-1-.
- Pull connector -2- off multi-function switch lead.
- Turn locking lever-3- and remove connector for transmission wiring harness.
- Cut cable tie -4-.

- Pull connector off sender for speedometer (arrow -A-).
- Unscrew engine speed sender -G28 (arrow-B-) from transmission.

- Remove ATF line holder-arrow- from engine oil pan.
- Place drip tray VAG 1306 underneath.
- Thoroughly clean area around ATF line/transmission.

- Separate ATF lines -1- to ATF cooler.
- Seal off ATF lines with clean plugs.
- Do not remove ATF line holder-3-.
- Remove transmission side starter motor bolt -2
- Remove starter.

- Unbolt torque converter from drive plate (3 securing bolts).
Turn crankshaft 1/3 turn for each bolt.

- Mark position of support bracket for securing selector lever cable to transmission housing (position must be correct when installing). Unbolt support bracket -arrow-.

- Remove selector lever cable from selector shaft lever-arrow-.
- Remove side and lower engine/transmission connecting bolts.

- Set up transmission support 3282.
Transmission support 3282 is set up with adjusting plate 3282/19 for automatic transmission 01V.
The symbols on the adjusting plate indicate the mounts required, the arrow points forward.

- Move jack VAG 1383A with transmission support 3282 under the transmission, align adjusting plate parallel to transmission and support transmission.
- Secure transmission to transmission support 3282 with bolt -A-.
- Checks page between transmission support and oil pan using washers.

- Remove left and right-hand engine mounting nuts-1-.
- Remove bolts -2- from transmission mounting to subframe.

- Before loosening the subframe, it is essential to check whether at least holes -1 and -2- are aligned on both sides of the vehicle using test drifts 3393.
If this is not the case, perform steering alignment measurements after tightening the sub-frame!

- Unscrew bolts -1- and -2- at rear of subframe on both sides of vehicle.
- Remove bolts -3- at front of subframe on both sides of vehicle.
- Remove bolts -4- (two on each side of vehicle):
- Take note when lowering the transmission that no components are damaged.

- Lower engine and transmission assembly 8 turns on spindles.
- To do this, lower engine and transmission assembly in stages alternatively on each spindle i.e. 2 turns at a time.
- At the same time, lower engine and transmission assembly on jack VAG 1383A (with aid of 2nd mechanic).
- Remove upper engine/transmission connecting bolts.
- Press transmission off engine and at the same time press torque converter out of drive plate.

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

- Secure torque converter to prevent it falling out.
When working on the transmission, it must be secured to the repair stand with transport device 3457 and retaining plate VW 309.

Installing
- Clean ATF cooler and ATF lines before installing an exchange transmission.
- Before installing transmission ensure that torque converter seats correctly in transmission.
- Before installing, ensure that the dowel sleeves are correctly located.
- The threaded holes in the flange shaft behind the transmission must be cleaned of all locking material residue.A thread tap is suitable for this.

- Secure transmission to transmission support 3282 with bolt -A
- Place transmission jack under vehicle.
- Guide transmission in between lowered subframe and underbody.
- Align transmission to engine.
- Screw engine/transmission connecting bolt hand-tight in each side.

- Bolt torque converter and drive plate together.
To do this, screw in bolts by hand and then tighten to 85 Nm.
- Install upper engine/transmission securing bolts and tighten to prescribed torque.
- Holders and Ground connections are fitted to some bolts.

- Lift engine and transmission assembly 8 turns on the spindle.
- To do this, lower engine and transmission assembly in stages alternatively on each spindle i.e. 2 turns at a time.
- At the same time, raise engine and transmission assembly on jack VAG 1383A (with aid of 2nd mechanic).
1. Subframe installation with wheel alignment
2. Subframe installation without wheel alignment
1. If holes -1- and -2- did not align before loosening subframe, picture N37-0916, the wheels must be aligned.
- Install subframe using bolts originally removed. These must be replaced following wheel alignment.
- When doing this, tighten original bolts only to prescribed torques.

WARNING!: The vehicle must not be driven in this state.

2. If holes -1- and -2- did align before loosening subframe, picture N37-0916, the wheels need not be aligned.
- Install subframe with new bolts. Observe tightening sequence.

- Fit left and right-hand engine mounting nuts -1-.
- Fit bolts -2- for transmission mounting to subframe.

- Once subframe is bolted to body and engine and transmission assembly is bolted to subframe, remove bolt -A-.
- Remove jack VAG 1338 A.
- Apply anti-corrosion agent to point of contact between bolt -A- and oil pan.
- Fit side and lower connecting bolts for engine to transmission and tighten to prescribed torque.

- Shift selector shaft lever into position "2" and carefully press ball head of selector lever cable -1- into selector shaft lever -2- e.G. using a pair of pliers.
The selector shaft lever -2- must not be bent when doing this, otherwise the selector mechanism will not be able to be adjusted correctly.
- Push selector lever cable -1- forward fully -arrow- to shift selector lever shaft -2- into position "2".

- Bolt support bracket of selector lever cable to transmission -arrows- at place marked.
- Install starter.

- Fit ATF lines -1- to engine/transmission assembly.

- Remove ATF line holder -arrow- from engine oil pan.

- Fit connector to multi-function switch -2-.
- Fit connector for transmission wiring harness and secure with locking lever-3-.
- Install noise insulation tray holder-1-.
- Replace cable tie -4-.

- Reconnect speedometer sensor connector -arrow A-.
- Screw engine speed sensor -G28- (arrow -B-) into transmission.

- Fit drive axles -1- to flanged shafts.
- Fit protective plates for left and right-hand drive axles -arrows-. The third bolt cannot be seen in the illustration.
- Install front exhaust system with catalyst.

- Install noise insulation tray -arrows-.
- Install front wheels.
- Remove support device 10-222 A.
- Fit intake hose to intake manifold.

- Fit engine cover and tighten bolts -arrows-.
- Reconnect Ground strap to battery.
- Perform self-diagnosis and basic setting using "guided fault finding" on VAS 5051.
- Enter radio code.
- Initialize electric windows, set clock.
- Check selector lever cable adjustment, adjust if necessary.
- With transmission installed, check final drive oil level.
- Check and top up ATF level.

- When checking ATF level, check ATF pipe connections -A- and -B- for leaks.

Tightening torques

Transmission to engine
1) with nut
2) with bracket for ATF lines
Pos. A = Dowel sleeves