Transmission, Removing and Installing

Transmission, removing and installing (vehicles with 4-cylinder TDI engine with pump injector unit), 01V, 5 SPD. A/T (AWD)

Special tools, testers and auxiliary items required:

^ Engine support bridge 10-222A
^ Bracket for engine 10-222A/1
^ Pry lever - mmv outside mirror 80-200
^ Engine sling 2024A
^ Transmission support 3282
^ Adjustment plate 3282/19

Special tools, testers and auxiliary items required:

^ Testing mandrel 3393
^ Attachment and holding rig 3457
^ Drip tray V.A.G1306
^ Torque wrench 550 Nm V.A.G1331
^ Torque wrench 40-200 NM V.A.G 1332
^ Engine-/gearbox jack V.A.G 1383 A

Special tools, testers and auxiliary items required

Bracket 30-211 A:

Step ladder VAS5085:

Removing
^ First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
^ Disconnect battery Ground (GND) strap with ignition switched off.

^ Pull out oil dipstick - 1 - from guide tube.
^ Unclip covers for nuts.
^ Unscrew nuts - arrows - and remove engine cover.
^ Unclip covers for nuts.

^ Unscrew nuts - arrows - and remove air filter cover.
^ Disconnect intake hose from intake manifold.

^ Unclip harness connectors - 1 - and - 2 - under coolant reservoir from bracket.
^ Remove intake manifold with intake manifold flap and Exhaust Gas Recirculation (EGR) valve.
^ Remove eyelet for engine sling 2024A.
^ Re-insert pin into center hole of engine sling 2024A and secure using cotter pin.
^ Attach Engine support bridge 10-222A in conjunction with bracket for engine 10-222A/1.

^ Hook engine sling 2024A into spindle of engine support bridge 10-222A.
^ Pre-tension engine/transmission assembly on the spindles.
^ Loosen wheel bolts.
^ Raise vehicle.
^ Remove front wheels.

^ Unclip retaining clamp for coupling rod - 1 - of Left Front Level Control System Sensor G78 from control arm - 2 -.

^ For vehicles with auxiliary heater, remove bolts - arrows - from exhaust pipe at noise insulation.

^ Remove noise insulation - arrows A and B -.
^ For vehicles with noise insulation - D -, remove bolts - arrows C -.

^ Remove noise insulation for drive axles from wheel housing at left and right - arrows -.
^ Remove front exhaust system with catalytic converter.

^ Remove shielding plate/drive axle - arrows - on right side. The third bolt is not visible in the illustration.
^ Unbolt left and right drive axles - 1 - from flanges and tie up.

^ Remove noise insulation holder - 1 -.
^ Disconnect connector - 2 - from wire for multi-function switch.
^ Swing securing lever - 3 -, disconnect connector for transmission wiring harness.
^ Cut cable tie - 4 -.

^ Disconnect connector for speedometer from transmission - arrow A -.
^ Place drip tray V.A.G. 1306 underneath.
^ Always clean area of ATF line/transmission connection.

^ Disconnect ATF lines from engine/transmission assembly - arrows - and tie up.
^ Plug ATF lines and transmission using clean plugs.
^ Remove starter motor.
^ Unbolt torque converter from drive plate (3 securing bolts).

To do this, turn crankshaft accordingly 1 3 additional rotation.

^ Remove heat shield - A - from vehicle floor.
^ Remove cover plate - B - - arrows -.
^ Disconnect propshaft from transmission.
^ Then slide propshaft back to stop and tie up.

^ Mark position of mounting bracket for selector lever cable to transmission housing for re-installation, unbolt mounting bracket - arrows -.
^ Remove side and lower connecting bolts for engine/transmission.

^ Position transmission support 3282.

Transmission support 3282 is attached to automatic transmission 01V using adjustment plate 3282/19.

The symbols on the adjusting plate indicate the mounts required, the arrow points forward.

^ Move engine-/gearbox jack V.A.G 1383 A with transmission support 3282 under the transmission, align adjustment plate parallel to transmission and support transmission.

^ Secure transmission on transmission support 3282 using bolt - A -.
^ Fill space between transmission support and oil pan with washers.

^ Before unbolting engine mount from subframe, mark installed position of bolts - 1 - and positioning sleeves - 2 -.

^ Remove nuts - 1 - at bottom on left and right engine mounts.
^ Remove bolts - 2 - transmission mount/subframe.

^ Before loosening subframe, check on both sides of vehicle, using testing mandrels 3393, that at least holes - 1 - and - 2 - align.

Hole - 3 -is not applicable here.

If this is not the case, axle alignment must be performed after tightening of subframe.

^ Remove 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 - (2 bolts at each vehicle side).

^ Unhook hose for power steering from bracket - arrow -.

When lowering transmission, ensure that no components are damaged.

^ Climb up step ladder VAS5085 in order to lower the engine/transmission assembly via the spindles.

^ Lower engine/transmission assembly via the spindles approximately 8 rotations.
^ At the same time lower engine-transmission-assembly using engine-/gearbox jack V.A.G 1383 A (second mechanic).

^ Pry off selector lever cable from lever/selector shaft - arrow -
^ Remove upper engine/transmission bolts.
^ Press transmission from engine, thereby press the torque converter out of the driving plate.

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

^ Using bracket 30-211 A, secure converter so it does not fall out.

Use workshop crane V.A.G. 1202A and attachment and holding rig 3457 to transport the automatic transmission.

Secure transmission to assembly stand using attachment and holding rig 3457 and holding plate VW309 when performing repair work.

Installing
^ Before installing a replacement transmission, ATF cooler and ATF lines must be cleaned.
^ Before installing transmission, make sure that torque converter is correctly inserted in transmission.
^ Make sure alignment bushings as well as intermediate plate is correctly seated on engine.
^ Threaded holes in flanged shaft at rear of transmission must be cleaned of locking compound residue. Cleaning can be performed using a thread tap.

^ Secure transmission on transmission support 3282 using bolt - A -.
^ Set transmission jack under the vehicle.
^ Guide transmission in between the lowered subframe and vehicle floor.
^ Align transmission to engine.
^ Insert and hand tighten one connecting bolt on both sides of the engine/transmission.
^ Bolt torque converter and drive plate to each other.

To do this insert bolts by hand and tighten to 85 Nm.
^ A bracket or a Ground (GND) connection is also fastened at some connecting bolts for engine/transmission.
^ Insert top engine/transmission connecting bolts and tighten to tightening torque.
^ Climb up step ladder VAS5085 in order to raise the engine/transmission assembly via the spindles.

^ Raise engine/transmission assembly via the spindles approximately 8 rotations.
^ At the same time raise engine/transmission-assembly using engine-/gearbox jack V.A.G. 1383 A (second mechanic).
1. Subframe installation with axle alignment
2. Subframe installation without axle alignment
1. If holes - 1 - and - 2 - did not align, illustration N37-0916, before loosening subframe, an axle alignment must be performed.

^ Install subframe using the old bolts. These must be replaced with new bolts after the axle alignment.
^ When doing this, tighten the old bolts to specified tightening torque.

CAUTION: Vehicle must not be driven in this condition.

2. If holes - 1 - and - 2 - did align, illustration N37-0916, before loosening subframe, an axle alignment must not be performed.

^ Install subframe with new bolts, observe tightening torque while doing so.

^ Bolt engine mount to subframe according to markings applied earlier for bolts - 1 - and alignment bushings - 2 -.

^ Thread on lower nuts - 1 - to engine mounts on left and right sides
^ Thread in new bolts - 2 - transmission mount/subframe.

^ After subframe is bolted to chassis and engine/transmission assembly is bolted to subframe, remove bolt - A -
^ Remove engine-/gearbox jack V.A.G 1383 A.
^ Apply corrosion protection to contact surface between bolt - A - and oil pan.
^ Thread in side and lower connecting bolts for engine/transmission and tighten to tightening torque.
^ Install retaining clamp for coupling rod of Left Front Level Control System Sensor G78 at left control arm at front.
^ Do not bend or kink selector lever cable, lightly grease coupling ring and ball socket with polycarbamide grease G052142A2 before installing.

^ Move lever/selector shaft - 2 - on transmission in - direction of arrow - to "2" and carefully press ball head of selector lever cable - 1 - on selector shaft lever using pliers.

Do not deform selector shaft lever - 2 - when pressing on or else shifting cannot be precisely adjusted any more.

^ Press selector lever cable - 1 - completely toward front - arrow - in order to shift the lever/selector shaft - 2 - to "2".

^ Bolt support bracket for selector lever cable firmly to transmission according to marking - arrows -.
^ Install starter motor.
^ Connect propshaft to flange.

^ Install cover plate - B - - arrows -.
^ Install heat shield - A - to vehicle floor.

^ Always replace O-rings - 1 -.
^ Coat new O-rings with ATF and insert.
^ Make sure that O-rings are seated properly so that they do not slip out of their seating when connecting ATF lines.
^ Push ATF lines into transmission by hand up to the limit stop.
^ Only tighten bolt - 2 - when ATF lines are completely connected.

^ Connect connector of multi-function Transmission Range (TR) switch - 2 -.
^ Connect connector for transmission wiring harness and secure using securing lever - 3 -.
^ Install noise insulation holder - 1 -.
^ Replace cable ties - 4 -.

^ Connect connector for speedometer Vehicle Speed Sensor (VSS) - arrow A -.

^ Install drive axles - 1 - to flanged shafts.
^ Install shielding plate/drive axle - arrows - on right side. The third bolt is not visible in the illustration.
^ Install front exhaust pipe with catalytic converter.

^ Install noise insulation for drive axles at wheel housing on left and right - arrows -.

^ Install noise insulation - arrows -.
^ In vehicles with auxiliary heater, bolt exhaust pipe firmly to noise insulation.
^ Install front wheels.
^ Remove engine support bridge 10-222A.

^ Engage hose for power steering into bracket - arrow -.
^ Install intake manifold with intake manifold flap and Exhaust Gas Recirculation (EGR) valve.

^ Insert harness connectors - 1 - and - 2 - into brackets under coolant reservoir.
^ Connect intake air duct to intake manifold.

^ Attach air filter cover and tighten nuts - arrows -.
^ Clip in covers for nuts.

^ Attach engine cover and tighten nuts - arrows -.
^ Clip in covers for nuts.
^ Insert oil dipstick - 1 - into guide tube.
^ Connect battery Ground (GND) strap.
^ Initialize electrical window regulators, set clock 36.
^ Code radio.
^ Check adjustment of selector lever cable and adjust if necessary.
^ Check gear oil in final drive with transmission installed.
^ Then check ATF level and top off.

^ Check ATF line connections - A - and - B - for proper seal when checking ATF level.

Tightening Torque

Transmission to engine

Item A = bushing