Removing and Installing

Removing and installing the Transmission
(vehicles with 8-cylinder engine)

Special tools and equipment

- 10-222A Pull-out device
- 10-222 A/1 Frame
- 10-222 A/2Extra hooks
- 10-222 A/1O Spindle
- 10-222 A/18 Adapter
- 80-200 Release lever
- 3282 Transmission mounting
- 3282/19 Adjustment plate
- 3393 Test mandrel
- 3457 Transport device

Special tools and equipment

- VAG 1306 Drip tray
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1383 A Engine/transmission hoist
- VAS 5085 Ladder

Removing

- Obtain code for radio.
- Switch ignition off and disconnect battery ground strap.
- Remove intake air duct upper part of air filter and intake hose.
- Drain coolant.

- Unclip connectors (arrows) from holder.
- Put lock barrel in service position:

- Unclip connector (arrow) for air conditioning compressor from holder.

- Disconnect oil filler neck from engine.
- Install pull-out device 10-222A with stands 10-222 A/1 and adapter 10- 222 A/18. Long edge of adapter 10-222 A/18 faces forward.
- Attach third spindle 10-222 A/1O with extra hook 10-222 A/2 to suspension eyelet on left rear of engine.
- Attach second hook 10-222 A/2 to eyelet on right rear of engine.
- Tension engine/transmission assembly slightly using spindles.
- Loosen wheel bolts.
- Raise vehicle.
- Remove front wheels.
- Remove front right wheel arch liner.
- Remove front exhaust pipes.

- Remove right and left drive shaft heat deflectors (arrows). Third screw is not visible in illustration.
- Unbolt drive shafts -1- from flanges on left and right and tie up.

- Remove heat shield -A- from floor of vehicle.
- Remove deflector-B- (arrows).
- Separate cardan shaft from transmission.
- Pull cardan shaft back to stop and tie up.

- Remove selector lever cable deflector.
- To facilitate re-installation mark position of mounting for selector lever cable to transmission remove bolt (arrow).

- Disconnect selector lever cable from lever/third motion shaft (arrow).

- Disassemble holder for sound insulator -1-.
- Disconnect wiring connector -2- for multi-function switch.
- Move safety lever -3- aside; disconnect connector for transmission wiring harness.
- Cut cable tie -4-.

- Disconnect connector from speedometer sensor -G22- (arrow).

- Remove engine speed sensor -G28- from lower mounting (arrow).

- Remove bolt-1- holding ATF lines -2-from engine.

- Place V.A.G 1306 or equivalent drip tray underneath.
- Thoroughly clean area where ATF line/transmission connect.
- Remove ATF lines from engine/transmission assembly (arrow) and tie up.
- Plug ATF lines and transmission with clean stoppers.

- Remove bolts (arrows) and remove stop for torque support -1-.
- Place V.A.G 1306 or equivalent drip tray underneath.

- Remove hex nut -1- for coolant pipe holder -2- from oil pan/engine. Remove coolant pipe as shown.
- Remove hex nut -3- for oil tube -4-. Pull oil tube out of oil pan and plug oil pan and tube with clean stoppers.
- Remove bolt -5- for wiring harness from right engine mount.

- Remove bolt (arrow) for air conditioning ducting from oil pan/engine.

- Unclip retaining bracket for coupling rod -1- of Left Front Level Control System Sensor -G78- from front left support guide -2-.

- Install transmission mounting 3282.

The transmission mounting 3282 for the O1V automatic transmission is installed with the 3282/19 adjustment plate.

The symbols on the adjustment plate show the mountings required; the arrow points in the direction of travel.

- Position V.A.G 1383 A hoist and 3282 transmission mounting under transmission align adjustment plate parallel to transmission and support transmission on it.
- Fasten transmission to 3282 transmission mounting using bolt-A-.
- Pack space between transmission mounting and oil pan with washers.

- Remove nuts -1- on lower left and right of engine bracket.
- Remove bolts -2- on transmission mount/support.
- Disconnect lines from the engine mountings unclip cables from assembly support and tie to one side.

- Before disconnecting assembly support it is vital to inspect both sides of vehicle using 3393 test mandrels to check that holes -1- and -2- (at least) are aligned.

If this is not the case, a suspension alignment must be carried out after the assembly support is tightened!

Hole -3- is of no relevance at this time.

- Remove bolts -1- and -2- at rear of assembly support on both sides of vehicle.
- Remove bolts -3- at front of assembly support on both sides of vehicle.
- Remove bolts -4- (2 on each side of the vehicle).

- Remove hex nut -2- for ground cable -1-from right engine bracket -3-.
- Loosen bolts (arrows) on right motor bracket and remove bracket.
- Disconnect electrical connections from alternator and remove wiring harness from alternator.
- Remove starter.

- Disconnect torque converter from drive plate (3 bolts). Turn crankshaft 1/3 of a turn to access each bolt.

- Using quick-release catch disconnect coolant hose (arrow) under left side rail from coolant pipe -not visible in picture-.

Make sure no components are damaged as the transmission is lowered.

- Climb up ladder (VAS 5058 or equivalent) in order to lower engine/transmission assembly with spindles.

- Lower engine/transmission assembly approximately 4 turns using spindles.
- Lower assembly using spindles lowering it alternately 2 turns.
- At same time lower engine/transmission assembly using V.A.G 1383 hoist (2nd mechanic).
- Unclip wiring for oxygen sensors on transmission.
- Remove engine/transmission connecting bolts.
- While pushing transmission away from engine press torque converter out of drive plate.

- Press torque converter against ATF pump (arrow).
- Carefully retract transmission and lower it.

- Take steps to prevent converter falling out.

Use a 3457 transport device for transporting the automatic transmission unit.

To install the unit the transmission together with the 3457 transport device and the VW 309 retaining plate is attached to the installation bracket.

Installing

- Before installing a replacement transmission unit clean ATF cooler secondary ATF cooler and ATF lines
- Before installing transmission make sure torque converter has been correctly inserted in transmission
- Ensure body-fit sleeves are seated correctly.
- Clean any adhesive residue from tapped holes in rear flanged shaft of transmission. This can be done using a tap thread.

- Fasten transmission to 3282 transmission mounting using bolt -A-.
- Position transmission hoist underneath vehicle.
- Position transmission between lowered assembly support and vehicle floor.
- Alternately lift and push transmission forward toward engine.
- Align transmission with engine.
- Insert a bolt on each side of engine/transmission assembly and screw finger-tight.

- Bolt converter and drive plate together. Insert bolts by hand and tighten to 85 Nm.

- Tighten engine/transmission bolt -1- using torque wrench.
- Insert engine/transmission bolt -2- and bolt for wiring harness -3- and thread in finger-tight.
- Place open side of holder for wiring harness -3- onto hex bolt head -1-.
- Tighten bolt -2- using torque wrench.
- Insert remaining engine/transmission bolts and tighten using torque wrench.
- A holder or ground connection is also screwed onto some of bolts.
- Clip harnesses for oxygen sensor onto transmission.
- Climb up ladder (VAS 5058 or equivalent) in order to lift engine/transmission assembly with spindles.

- Lift engine/transmission assembly approximately 4 turns using spindles.
- Lift assembly using spindles raising it alternately 2 turns.
- At same time raise engine/transmission assembly using VAG 1383 hoist (2nd mechanic).

- Using quick-release catch connect coolant hose (arrow) under left side rail to coolant pipe -not visible in illustration-.
- Install starter.
- Connect electrical connections to alternator and fasten wiring harness to alternator.

- Install right engine bracket -3- and tighten bolts (arrows).
- Attach ground cable -1- to right engine bracket using hex nut -2-.

1. Installing the assembly support with a suspension alignment measurement

2. Installing the assembly support without a suspension alignment measurement

1. If holes -1- and -2- were not aligned before the assembly support was removed suspension alignment must be performed.

- Install assembly support using old bolts. These must be replaced by new bolts after suspension alignment has taken place.
- Tighten old bolts only to specified tightening torque.

Caution: The vehicle must not be driven in this condition.

2. If holes -1- and -2- were aligned before the assembly support was removed a suspension alignment does not have to be performed.

- Install assembly support using new bolts observing tightening sequence.
- Tighten nuts -1- on lower left and right of engine bracket.
- Tighten transmission mount/assembly support bolts -2-.

- Remove bolt -A- when assembly support has been bolted to body and engine/transmission unit has been bolted to assembly support.
- Remove V.A.G 1338 A hoist.
- Apply an anti-corrosion agent at the point where bolt-A- touches the oil pan.
- Clip lines for engine mounted onto assembly support and attach lines to engine mount.

- Install bolt (arrow) for air conditioning ducting to oil pan/engine.
- Attach retaining bracket for coupling rod to Left Front Level Control System Sensor -G78- from front left support guide.

- Install bolt -5- for wiring harness onto right engine mount.
- Insert oil tube -4- into oil pan and tighten hex nut -3-.
- Install coolant pipe -2- and tighten hex nut-i- for coolant pipe bracket on oil pan/engine.

- Attach stop for torque support -1 - and tighten bolts (arrows) to specified tightening torque.

Note: Always replace 0-rings -1-.

- Moisten 0-rings with ATF.
- Ensure that 0-rings are seated correctly so they do not slip out of position when ATF lines are inserted.
- Insert ATF lines by hand into transmission until they can go no further.

Note: Do not tighten screw -2- until the ATF lines have been fully inserted.

- Screw ATF line holder-2-to engine 11 -hex cap screw.

- Install engine speed sensor -G28- to lower mounting (arrow).

- Attach connector to speedometer sensor -G22- (arrow).

- Attach multi-function switch connector-2-.
- Attach connector for transmission wiring harness and secure using safety lever -3-.
- Attach bracket for sound insulation -1-.
- Replace cable tie -4-.

- Move lever/third motion shaft to "2" and carefully press ball end of selector lever cable -1- onto lever of third motion shaft using forceps, for example.

Note: Ensure the lever of the third motion shaft -2- is not bent during this operation as it will otherwise not be possible to adjust the gearshift exactly.

- Install selector lever cable block tight according to marking on transmission (arrow).
- Attach deflector/selector lever cable.

- Attach deflector -B- (arrows)
- Attach heat shield -A- to floor of vehicle.

- Attach drive shafts -1- to flanged shafts.
- Remove right and left drive shaft heat deflectors (arrows). Third screw is not visible in illustration.
- Install front exhaust pipes.
- Install right front wheel arch liner.
- Install front wheels.
- Remove removal device 10-222 A.
- Attach oil filler neck to engine.

- Clip connector (arrow) for air conditioning compressor into holder.
- Install lock barrel and fittings.
- Clip connectors (arrows) into holder.
- Fill engine with coolant.
- Install intake air duct upper part of air filter and intake hose.
- Connect ground strap to battery.
- Perform On Board Diagnostic (OBD) and basic setting using VAS 5051.
- Code radio.
- Initialize power windows; set clock.
- Check selector lever cable and adjust if necessary.

- Clip connectors (arrows) into holder.
- Fill engine with coolant.
- Install intake air duct upper part of air filter and intake hose.
- Connect ground strap to battery.
- Perform On Board Diagnostic (OBD) and basic setting using VAS 5051.
- Code radio.
- Initialize power windows; set clock.
- Check selector lever cable and adjust if necessary.
- If transmission installed check transmission oil in final drive.
- Check ATF level and top up.

- Check connections -A- and -B- of ATF lines while checking ATF level (look for leaks).

Removing and Installing

Torque Sequence:

Tightening Torques: