Transmission, With All Wheel Drive

Passat and CC Specific Components

Transmission, with All Wheel Drive

Short Description

- Before removal, print out the diagnostic protocol. Send the removed transmission together with the protocol back in the usual manner.

The transmission is removed downward as a unit. The engine remains in the vehicle.

The battery tray, air filter housing and engine cover are removed from the top. The engine with transmission are then supported so that the transmission mount bracket can be removed.

After removing the bevel box, support the transmission, remove the last bolt connecting the engine and transmission and lower the transmission.

• The subframe is not removed.

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine and Transmission Jack (V.A.G 1383 A)

• Spring Type Clip Pliers (VAS 5024A)

• Vehicle Diagnosis, Testing and Information System (VAS 5051B)

• Drip Tray for VAS 6100 (VAS 6208)

• Engine Support Bridge (10 - 222 A)

• Engine Support Adapter (10 - 222 A/3)

• Adapter (10 - 222 A/13)

• Adapter (10 - 222 A/16)

• Transmission Support (3282)

• Hose Clamps Up to 25 mm Dia. (3094)

• Adjusting Plate (3282/56)

• Wedge Tool (T10161)

• Assembly Tool (T10071)

• Bracket (T10013)

• Socket SW15 (V/175)

• Counterhold Tool Touareg V10 (T10172)

Removing

- Before removing, print out a diagnostic protocol for this vehicle. Before sending the transmission back in the usual manner, secure the protocol to the transmission so that it is not lost during transportation.

- Lift the vehicle, all 4 lift points of the hoist are at the same height.

- Turn the steering to the center position.

- Remove the ignition key and engage the steering wheel lock.

- Place the selector lever in the P position.

- Loosen both drive axle bolts - arrow -.





• Do not place the vehicle on the ground after loosening the bolts.

- Remove both front wheels.

• To make it possible to rotate the driveshaft later so it can be loosened:

- Place the selector lever in the N position.

- Remove the ignition key and engage the steering wheel lock.

- Disconnect the battery.

- Remove the air filter housing and retaining plate.

- Disconnect all electrical connectors to transmission and starter that are easily accessible from above:

• Multifunction transmission range switch

• Starter

• Ground (GND) strap to bracket

- Disengage the selector lever cable from the transmission by hand - 1 - and pull it out of the bracket - 2 -.





Handle with care and make sure not to kink the cable. Do not use pliers, otherwise the retainer straps may break off.

- Pry the cable - 1 - off the shift rod ball head - 3 - using an open end wrench - 2 -.





CAUTION!
When opening the coolant expansion tank, hot steam could escape. Wear eye protection and protective clothing to prevent eye injuries and scalding. Cover the cap with a cloth and open carefully.

- Remove the coolant expansion tank cap.

- Clamp off the coolant hoses using (3094) and remove the hoses.





- Remove the coolant lines - 1 and 2 - from the engine and disengage the wiring harness.





- Remove all upper engine/transmission bolts.

It is advisable to complete the work under the vehicle now. This prevents the weight of the engine from weighing on the (10 - 222 A) for a long period of time.

- Remove the noise insulation tray and lower part of the left front wheel housing liner.

- Remove the ball joint to lower control arm nuts - arrows - for both lower control arms.





- Disconnect the connector from the left front level control system sensor (G78).

- Press both drive axles from the transmission and remove them.

- Remove the pendulum support, first remove bolt - A - and then bolts - B -.





- Remove the right drive axle heat shield bolts - arrows - and shield.





- Mark the position of the driveshaft rear flexible disc to the bevel box output flange.

- Remove the driveshaft rear flexible disc to output flange bolts - arrows -.





- Counter hold the rear final drive to loosen and tighten the driveshaft bolts.





• To loosen the next bolt, rotate the driveshaft by turning the rear wheels.

The seal - arrow - in the driveshaft must not be damaged.





- Clamp the (T10071) with a cloth. This protects the seal.





- Remove the bracket - A - between the engine block and bevel box.





- Remove the upper bevel box to transmission bolts - arrows -.





- Remove the lower bevel box to transmission bolts - arrows -.





- Disconnect the connector - 1 - from the oil level thermal sensor (G266).





- Press the engine and transmission forward by hand and secure it in this position with a suitable wood block - A -.

- Carefully press the bevel box off the transmission and remove it downward.

- Remove the plug.





- Remove the six torque converter nuts through the opening using (V/175). While doing so, counter hold at the starter ring gear using a screwdriver.

- Remove all easily accessible bolts between the engine and transmission except for one.

- Disconnect the two electrical connectors to the transmission that are easily accessible from below.

- Clamp off the Automatic Transmission Fluid (ATF) lines - 2 - using (3094).

- Remove the bolt - 1 - and pull the ATF lines - 2 - out of the transmission.





- Plug the transmission and ATF lines using clean plugs.

- To ensure the rear engine support bridge spindle has sufficient clearance, remove the intake hose from the throttle valve unit and lay aside.

- Install the (10 - 222 A).





- Secure the engine/transmission and support it. Do not lift.





- Remove the transmission mount to bracket bolts - 1 -.





- Remove the transmission mount bracket - 2 - bolts from the transmission.

- Lower the engine/transmission using the (10 - 222 A) spindles about 6 turns.

- Remove the transmission mount bracket.

- Align the (3282) with (3282/56).

- Guide the (V.A.G 1383 A) under the transmission and support the transmission. Do not lift.

The transmission is separated from the engine in this position.

- Remove the last engine/transmission bolt.

- Carefully drain the transmission, ensure clearance to other components.

- You should have permanently attached the transmission's diagnostic protocol for analysis to the transmission and ready it for shipment.

Installing

Installation is performed in the reverse order of removal. However, important steps are shown here:

- Make sure the alignment sleeves are seated correctly between the engine and transmission.

- Position the transmission, possibly readjust the transmission mount.

- Install a engine/transmission bolt.

- Install all torque converter nuts and tighten.

- Install the transmission mount bracket - 2 - to the transmission, tightening specifications.





- Raise the engine/transmission, reestablish the old seating of the transmission mount to bracket bolts - 1 - and tighten.





- Install the bevel box. Refer to => [ Bevel Box ] Bevel Box.

- Adjust the selector lever cable. Refer to => [ Selector Lever Cable, Adjusting ] Adjustments.

Do not grease the cable.

- Replace the seals on the ATF lines.

- Check the ATF level after installing. Refer to => [ Automatic Transmission Fluid Level, Checking and Filling ] Automatic Transmission Fluid Level, Checking and Filling.

- Check the coolant level and fill if necessary.

- Perform the basic setting by pressing Perform Basic Setting.

- Press ->.

- Press ->.

Tightening Specifications





1 - Driving Direction

- Drive Plate to Torque Converter

• 60 Nm

• Quantity: 6

• Remove and install using (V/175).

- M12 Bolts

• 80 Nm

- M10 Bolts

• 40 Nm

• These bolts are located at the bottom of the flange.

Arrows - Alignment Sleeves