Removing and Installing
Transmission, removing and installing for vehicles with 8-cyl. injection engine
Special tools and equipment
^ 10-222A Support
^ 10-222A/1 Support
^ 10-222 A/2 Auxiliary hooks
^ 10-222 A/10 Spindle
^ 10-222 A/18 Adapter
^ 3282 Transmission support
^ 3282/12 Adjustment plate
^ 3393 Test mandrel
^ T40013 Transportation device
^ VAG 1306 Drip tray
Special tools and equipment
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383A Engine/transmission jack
Additional information
^ Refer to Steering and Suspension
Removing
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove intake air duct, air cleaner and intake hose.
- Bring lock carrier into service position:
Refer to Body and Frame; Radiator Support
- Unclip connectors (arrows) from retainer.
- Remove connector from coolant expansion tank.
- Unbolt coolant expansion tank and place to one side. Do not open coolant system.
- Remove oil filler pipe from engine.
- Fit support bar 10-222A together with legs 10-222 A/1 and adapter 10222 A/18.
Longer side of adapter 10-222 A/18 faces forward.
- Secure third spindle 10-222 A/10 with additional hook 10-222 A/2 on lifting eye at rear left of engine.
- Hook second additional hook 10-222 A/2 on lifting eye at rear right of engine.
- Take weight of engine/transmission assembly onto spindles.
- Loosen wheel bolts.
- Raise vehicle.
- Remove front wheels.
- Remove sound insulation tray (arrows).
- Remove sound insulation tray bracket.
- Remove front exhaust pipes.
- Remove protective plates for left and right-hand axle shafts (arrows). Third bolt cannot be seen in illustration.
- Disconnect left and right-hand axle shafts -1- from flanges and tie-up.
- Remove cover plate (arrows).
- Disconnect driveshaft from transmission.
- Push driveshaft back onto limit stop.
- Press driveshaft up onto heat shield with a wooden wedge (arrow).
- Remove Engine speed (RPM) sensor -G28- from top left of transmission housing (arrow).
- Disconnect speedometer sensor connector.
- Disconnect back-up light connector.
- Unclip wires for speedometer, oxygen sensor and back-up light from transmission.
- Remove screws (arrows) and take off torque rod limit stop -1-.
- Mark installation position (item -1-) of both engine mountings from below.
- Remove left and right-hand engine mounting nuts -1-.
- Remove wiring harness retainer from right engine mount.
- Pull vacuum lines off engine mountings, unclip line from subframe and tie to side.
- Remove bolts -2- from transmission mounting to subframe.
- Unclip coupling rod retaining clamp -1- of Left front level control system sensor -G78- from left control arm -2-.
- Check whether holes -1- and -2- are aligned on both sides of vehicle using test drifts 3393.
- If the holes are not aligned, perform steering alignment measurements after tightening the subframe!
Note: Disregard hole -3-.
- Place transmission jack VAG 1383A with 1359/2 under subframe and exert slight counter-pressure.
- A - Block of wood
- Unscrew bolts -1- and -2- at rear of subframe on both sides of vehicle.
- Using transmission jack VAG 1383A, lower subframe slightly.
Note: Push rod -1- and connecting rod -2- securing bolts must be accessible.
- Remove selector mechanism from transmission as follows:
- Unbolt connecting rod -2- for selector rod from right side of transmission.
- Remove push rod -1- by unbolting hex socket head bolt.
- Remove nut -1- and pull gear selector -2- from selector shaft of transmission.
- Remove transmission jack VAG 1383A with 1359/2 from under subframe.
- Remove bolts -A- at front of subframe on both sides of vehicle.
- Remove bolts -B- (two on each side of vehicle).
- Place drip tray VAG 1306 or equivalent underneath.
- Remove oil pressure line retainer (arrow) from engine.
- Separate oil pressure lines -A- and -B-.
- Remove bolt (arrow -1-) from final drive cover.
- Remove oil pressure lines (arrow -2-) on transmission and pull out to side.
- Disconnect oil pressure lines (arrows) on transmission and seal holes with plugs.
- Remove oil pressure lines.
- Remove engine/transmission lower connecting bolts from engine side.
- Lower engine and transmission assembly approximately 4 turns on spindles.
- Remove clutch slave cylinder (arrow -1-) with heat shield (arrow -2-) and secure with wire without opening clutch hydraulic system.
Note: Do not depress clutch pedal.
- Mount transmission support 3282, adjustment plate 3282/12 for "01E" transmission and support elements as follows to transmission jack:
- Place adjustment plate 3282/12 on transmission support 3282 (adjustment plate fits only in one position).
- Align arms of transmission support according to holes in adjustment plate.
- Bolt on support elements -A- as illustrated on adjustment plate.
- Place transmission jack under vehicle, arrow symbol -B- (illustration V34-2931) on adjustment plate pointing to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Remove upper engine/transmission securing bolts (arrows).
Note: The bolt (arrow -A-) can only be unbolted (cannot be pulled out). Remember this when reinstalling.
- If bracket -1- is installed, set it aside with lines and secure with wire.
- Remove upper securing bolt on starter (arrow -B-).
- Remove nut (arrow -C-) from starter lower securing bolt (arrow -D-).
- Remove engine/transmission connecting bolt (arrow -E-).
- Press transmission off dowel sleeves.
- Guide transmission straight off engine until starter lower securing bolt -A- is no longer in its hole in transmission (arrow).
Note: When doing this take heed of the engine/transmission securing bolt (illustration N34-1493, arrow -A- in the vicinity of the right-hand catalyst).
- Lower transmission carefully, ensuring there is sufficient clearance at axle shafts, driveshaft and subframe.
- When work is performed on the transmission, it must be secured to the engine/transmission support VW 540.
Transporting the transmission
- Mount transportation tool T40013 to transmission lifting eye and secure.
- Secure workshop crane hook at 4th attachment point (arrow) on transportation tool.
- Lift transmission with workshop crane and transportation tool T40013.
Installing
- When replacing transmission transfer transmission supports complete with transmission mounting (torque settings.
- Clean input shaft splines and lightly grease with GOOD 100 grease.
- The clutch plate must be able to slide lightly back and forth on the input shaft.
- Check clutch release bearing for wear and replace if necessary.
- If plastic ring of release bearing is loose, glue it back on to release bearing with adhesive AMV 195 KD1 01.
- Three rectangular tabs (arrows) on plastic ring engage in notches of release bearing.
- If grooves are deeper than 0.5 mm, release bearing must be replaced.
- Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block, install if necessary.
- Thinly coat clutch release lever surface contacting plunger with copper grease.
- Before assembly, without exception, use a thread cutter to clean locking fluid residue from transmission flanged shaft threaded holes for driveshaft.
- Mount transmission support 3282, adjustment plate 3282/12 for "01 E" transmissions and support elements as follows to transmission jack:
- Place adjustment plate 3282/12 on transmission support 3282 (adjustment plate fits only in one position).
- Align arms of transmission support according to holes in adjustment plate.
- Bolt on support elements -A-, as illustrated on adjustment plate.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another.
- Lock safety support (arrow) on transmission.
- Place transmission jack under vehicle with arrow symbol.
- Before installing transmission, install engine/transmission connecting bolt (arrow -A-) in respective hole on transmission housing.
- Raise transmission carefully ensuring sufficient clearance at axle shafts, driveshaft and subframe.
- Align transmission to engine, and guide lower securing bolt -A- into respective hole of transmission housing (arrow).
Note: When doing this take heed of the engine/transmission securing bolt (illustration N34-1493, arrow -A- in vicinity of right-hand catalyst).
- Insert transmission.
- Install bracket -1- with lines onto engine/transmission securing bolts.
- Tighten engine/transmission upper securing bolts (arrows) and (arrow -A-) to prescribed torque.
- Tighten starter upper securing bolt (arrow -B-) and nut -C- to prescribed torque.
- Remove transmission jack from transmission after transmission is bolted to engine.
- Tighten engine/transmission securing bolt (arrow -E-) to prescribed torque.
- Install slave cylinder along with retainer for line/hose.
- Press heat shield (arrow -1-) onto slave cylinder and tighten bolt (arrow -2-) to prescribed torque.
- Install Engine speed (RPM) sensor -G28- on transmission housing.
- Install oil pressure lines between engine/transmission assembly and subframe.
- Replace seals on oil pressure lines.
- Tighten oil pressure lines on transmission to prescribed torque.
- Install oil pressure line securing bolt to transmission (arrow -2-) and tighten to prescribed torque.
- Install bolt (arrow -1-) to final drive cover and tighten to prescribed torque
- Install oil pressure line retainer (arrow) on engine.
- Reconnect oil pressure lines -A- and -B- to cooler connecting point.
- Install side and lower engine/transmission connecting bolts and tighten to prescribed torque.
- Lift engine and transmission assembly approximately 4 turns on spindle. Start with spindle 10-222 A/10.
- Press gear selector of selector rod -2- onto transmission selector shaft.
- Tighten nut.
- Bolt push rod -1- together with washers (if part of original equipment) to transmission.
- Bolt connecting rod -2- for selector rod to right-hand side of transmission.
Note: If the push rod securing bolt cannot be installed (transmission not raised sufficiently), then install the push rod after raising the subframe.
- Clip oxygen sensor wiring onto transmission.
- Connect back-up light connector.
- Connect speedometer sender connector.
- Install subframe: