Transmission, Removing and Installing

Transmission, removing and installing
Special tools and equipment





^ 10-222 A Support
^ 10-222A/1 Support
^ 10-222 A/2 Special hook
^ 10-222 A/3 Adapter
^ 3094 Hose clamps
^ 3282 Transmission support

Special tools and equipment





^ 3282/27 Adjustment plate
^ 3282/48 Pins (Qty. 2)
^ 3282/52 Support
^ 3300 A Engine support
^ 3336 Transmission lifting beam
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383 A Engine/transmission jack

Special tools and equipment





^ VAS 5024 Assembly pliers





^ T10036 Support rail

Removing

Note: Check whether a coded radio is installed as during the forthcoming work sequences the battery Ground strap must be disconnected. Obtain radio code first, if necessary.

^ Remove cover from engine.
^ With ignition switched off disconnect battery Ground strap.
^ Remove 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 cable support bracket from transmission (arrows).





^ Pull lock washer (arrow -1-) from gate selector cable relay lever -A-.
^ Remove gear selector cable -B- with transmission selector lever by removing nut (arrow 2).

Note: Use puller such as Kukko 20-10, if necessary.

^ Remove power steering pipe (arrow -3-).





^ Pull connector off speedometer sensor (arrow).





^ Remove wiring (arrow -1-) from starter.
^ Disconnect reverse light connector (arrow -2-).
^ Remove cable retainer (arrow -3-) on starter.
^ Remove upper securing bolt on starter.





^ Clamp clutch slave cylinder hose with special tool 3094.
^ Pull out clamp (arrow) and line/hose in direction of arrow.

Note: Do not depress clutch pedal.





^ Remove Ground strap at engine/transmission upper securing bolt.
^ Remove engine/transmission upper securing bolts.
^ If there are hoses and cable connections in area of engine mounting eye for support 1 0-222A, remove these.





Vehicles with 4 Cyl. engines
^ Install support bar 1 0-222A together with legs 10-222 A/1, special hook 10-222 A/2 and adapter 10-222 A/3.





Vehicles with 6 Cyl. engines
^ Install support bar 1 0-222A together with legs 10-222 A/1, special hook 10-222 A/2 and adapter 10-222 A/3.

Continued for all vehicles
^ Take weight of engine/transmission assembly on the spindles.
^ Turn wheels fully onto left lock.
^ Raise vehicle





^ Remove noise insulation tray -arrows-.





^ Remove left sound insulation -arrows-.

Vehicles with Diesel engines
^ Remove charge air line between charge air cooler and turbocharger.

Continued for all vehicles
^ Remove right sound insulation.
^ Disconnect drive shafts from flanged shafts and tie up as high as possible. When tying up shafts do not damage body surface protection.
^ Separate exhaust system and if necessary remove from sub-frame.





^ Remove pendulum support (arrows A and B).
^ Remove power steering pipe from starter and transmission.
^ Remove starter.





^ Unbolt engine side of assembly mounting from engine carrier from above -arrows-.





^ Remove left assembly mounting -2- hex bolts -arrows- from left mount -1-.
^ Carefully tilt engine and transmission by lowering left-hand spindle approximately 60 mm on support bar 10-222A





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





^ Pull off gate selector cable -A- with relay lever in direction of arrow.
^ Tie up selector cable with transmission selector lever and gate selector cable with relay lever.
^ Incline engine/transmission assembly further by lowering it via left spindle of support bar 10-222A.





^ Bolt support rail T10036 to both pendulum support securing holes on subframe (bolts -A-).
^ 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.

^ Remove lower rear engine/transmission securing bolts (arrow -A-).
^ Remove lower engine/transmission securing bolts.
Set up transmission support 3282 with adjustment plate 3282/27 to remove transmission 02M.
^ Align arms of transmission support according to holes in adjustment plate.





^ Bolt support elements -A-, as illustrated, on adjustment plate.





^ Place transmission jack under vehicle. Arrow symbol -B- (= Illustration N34-1052) 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).
^ Press transmission off dowel sleeves and carefully swing toward subframe.
^ Lower transmission slightly and incline to left via spindles of transmission support 3282.
^ Lower transmission carefully, guiding right-hand flange shaft in area of flywheel and left-hand flange shaft in area of subframe.
^ When lowering the transmission change position of transmission using transmission support 3282 spindles.

Note: Do not damage power steering line when lowering transmission.