Transmission, Removing and Installing
Transmission, removing and installing, 02E, 6 SPD. DSG A/T
Special tools and equipment:
- 10-222 A Support assembly
- 10-222 A/8 Adapter
- 10-22212 A Shackle
- 3094 Hose clamps
- 3282 Transmission support
- 3282/42 Sole plate
Special tools and equipment:
- V.A.G 1331 Torque wrench
- V.A.G 1332 Torque wrench
- V.A.G 1383 A Engine/transmission jack
Removing
Note: All cable ties which are unfastened or cut open when removing the transmission, must be replaced in the same position when installing the transmission.
- Remove engine cover.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground (GND) strap.
Note: Do not bend hoses when removing power steering reservoir from battery carrier.
- Tie reservoir up on lock carrier.
- Remove battery and battery carrier:
Note: Observe the required measures before disconnecting the battery.
- Remove intake hose -1- and disconnect connector -2- off mass air flow sensor
- Remove bolts -3- and -4-.
- Remove complete air cleaner.
- Remove starter:
- Unscrew nut (arrow -A-) and remove Ground (GND) strap -1-.
- Remove bolt (arrow -B-).
- Bolt (arrow -B-) is located in recess next to starter passageway to flywheel.
- Disconnect gear oil cooler hoses with hose clamps -3094-.
- Open clamps -1- and disconnect hoses from gear oil cooler.
- Seal off gear oil cooler with clean plugs.
- Remove upper bolts that connect engine to transmissions.
- Remove central switch -1-. To do this turn lever (arrow) in direction of (arrow) and pull central switch off.
- Install support device 10-222A with adapters 10-222 A/8.
Note: Do not seat adapter 10-222 A/8 on securing bolts for front fender
- When hoses or wiring are still located in vicinity of engine lifting eyes for support assembly 10-222 A remove them now.
- Secure left-hand spindle (transmissions side) to engine lifting eye using shackle 10-222 A/12 if necessary.
- Pretension engine assembly by means of spindles.
- Remove both front wheels.
- Remove sound insulation.
- Remove underseal -1- (arrows).
- Remove all cables and brackets from transmission oil pan.
- Remove selector cable from transmission. To do this remove bolts -A- for support bracket.
- Remove lock washer (arrow) and selector cable from selector shaft lever.
Note: Do not kink selector lever cable.
- Remove pendulum support -1- (arrows).
- Remove right hand inner constant velocity joint protective cover from engine if installed.
- Disconnect drive axles at transmission flanges.
- Raise right drive axle and secure.
- Turn steering to left lock.
- Mark installed position of swivel joint bolts (arrows) on control arm.
- Remove bolts (arrows).
- Disconnect left-hand coupling rod -1- from control arm and turn coupling rods upward.
- Swing wheel bearing housing outward.
- Guide left drive axle -2- out between subframe and transmission.
- Lift drive axle and secure to suspension strut using wire.
- Unbolt front exhaust pipe bracket on subframe (arrows) and unhook.
- Disconnect exhaust system after front exhaust pipe:
- Tie exhaust system up.
Note: The flexible element of the exhaust system must not be bent more than 10° otherwise it will be damaged.
- Remove subframe:
- Unscrew hydraulic line -1- from transmission console (arrow -A-).
- Remove bolts (arrows -B-).
- Carefully tilt engine with transmission. To do this lower left-hand spindle (transmission side) on support assembly 10-222 A approximately 100 mm.
- Remove transmission console -1- (arrows).
- The transmission support 3282 is set up with adjusting plate 3282/42 to remove the 6 Spd. Direct Shift Automatic Transmission 02E
- Position adjusting plate 3282/42 onto transmission support and align arms of transmission mounting with holes in adjusting plate.
- The arrow symbol -B- points in the direction of travel.
- Screw mounting elements -A- and -C- (pin 3282/29) into transmission support as shown on adjusting plate.
- Position transmission jack under vehicle.
- Align adjustment plate parallel to transmission.
- Screw pin 3282/29 into transmission.
- Secure transmission on transmission support 3282 with bolt (arrow).
- Support transmission from below by lifting transmission bracket.
- Remove engine/transmission lower connecting bolts.
- Press transmission off engine.
- Carefully lower transmission and observe that no wiring is catching.
Installing
- Check whether dowel sleeves for centering engine/transmission are in cylinder block, install if necessary.
- The transmission support 3282 is set up with adjusting plate 3282/42 to install the 6 Spd. Direct Shift Automatic Transmission 02E.
- Position adjusting plate 3282/42 onto transmission support and align arms of transmission mounting with holes in adjusting plate.
- The arrow symbol -B- points in the direction of travel.
- Screw mounting elements -A- and -C- (pin 3282/29) into transmission support as shown on adjusting plate.
- Position transmission jack under vehicle.
- Align adjustment plate parallel to transmission.
- Screw pin 3282/29 into transmission.
- Secure transmission on transmission support 3282 with bolt (arrow).
- Carefully raise transmission and bring transmission support 3282 into installation position.
- Insert transmission and observe that no wiring is catching.
- Install all engine/transmission connecting bolts (items -1- to -6-).
- Observe that bolt (arrow -B-) is installed.
- Install Ground (GND) strap (arrow -A-).
- Install assembly mountings as follows:
- Install transmission console -1- with new hex bolts to transmission (arrows) and tighten to specified torque.
- Pull transmission carefully up to transmission mounting using support assembly spindles.
CAUTION: Before installing the transmission bracket/transmission console bolts, it is essential to ensure that the bracket and mounting are absolutely parallel to one another otherwise the threads will be damaged.
- Install new hex bolts (arrows -B-) of assembly mounting left side and tighten to specified torque.
- Install hydraulic line -1- (arrow -A-).
CAUTION: Do not remove the engine support bridge 10-222A until the bolts on the left and right-hand sides have been tightened to proper torque.
- Install selector cable on transmission. To do this install bolts -A- for support bracket.
Note: Do not kink selector lever cable.
- Install lock washer (arrow).
- Install all cables and brackets to transmission oil pan.
- Install assembly:
- Install pendulum support -1-.
- Install drive axles:
- Install coupling rod and swivel joint:
- Install starter motor:
- Install underseal -1- (arrows).
- Bolt front exhaust pipe bracket on subframe (arrows).
- Connect exhaust system to front exhaust pipe:
- Install sound insulation.
- Install central switch.
- Connect transmission oil cooler hoses and secure with clamps.
- Install battery and battery carrier:
- Observe required measurement before and after reconnecting battery:
- Check selector lever cable adjustment, adjust cable if necessary.
- Enter radio code:
Tightening torques
Transmission to engine
- Replace bolts.
1) Double stud with M8 threaded stud
A: Dowel sleeves (for centering)
Transmission console -1- to transmission
Replace bolts.
Transmission console to transmission mounting
- Replace bolts.
Pendulum support -1- to transmission and subframe
- Replace bolts.
Note: Install engine/transmissions mountings stress free.
All other bolted connections:
