Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Adapter (VW 771/40) from Slide Hammer-Complete Set (VW 771)
• Engine Support Bridge (10-222 A)
• Engine Support Adapter (10-222 A/3)
• Engine Support Feet (10-222 A/8)
• Hose Clamps up to 25 mm dia. (3094)
• Transmission Support (3282)
• Pin (3282/29)
• Adjustment Plate (3282/33)
• Transmission Support Jig (3336) (for transporting the transmission)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Bracket (T10346)
• Grease for Clutch Plate Splines (G 000 100)
• Transmission Support Elements (determine when mounting the adjustment plate on the transmission support)
• M10 x 20 Collar Bolt
• M6 x 80 Collar Bolt
- First, check whether a coded radio is installed. If so, obtain the anti-theft code.
- Turn off the ignition and disconnect the battery ground cable.
- Remove the engine cover, if it is blocking the lifting eyes.
- Remove the complete air filter housing if it is located near the battery.
- Remove the battery and the battery tray.
- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 - and remove the cable from the pin - arrow -.
With a Metal Relay Lever:
- Remove the selector cable lock washer - 4 - from the relay lever - 2 - and remove the cable from the pin - arrow -.
With a Plastic Relay Lever:
Disconnecting the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must first be removed from the selector lever.
- Pull the locking mechanism all the way forward in the - direction of arrow 1 - and then unlock it to the left in the - direction of arrow 2 -.
- Press the relay lever forward (in the - direction of arrow 3 -).
- The plastic relay lever is removed together with the cable retainer later in the procedure.
Continuation for all:
- Remove the cable bracket bolts/nuts - arrow - from the transmission, move it to the side and tie it up.
Vehicles with a pipe between the clutch master and slave cylinders:
- Clamp off the supply hose to the master cylinder using a hose clamp up to 25 mm dia. (3094).
Vehicles with a hose/line assembly between the clutch master and slave cylinders:
- Clamp off the hose on the hose/line assembly - A - to the clutch slave cylinder using a hose clamp up to 25 mm dia. (3094).
Continuation for all:
- Pull the clip - arrow - for the hose/line assembly or pipe out to the stop.
- Remove the hose/line assembly or pipe from the breather assembly/slave cylinder and seal it off.
Do not press the clutch pedal anymore.
- Remove the ground strap - 1 - from the top starter bolt.
- Disconnect the connector - 2 - from the backup lamp switch (F4).
- Disconnect the connector and the wire from the starter.
- Remove the upper engine/transmission bolts - arrows -.
- Remove the upper bolt from the starter.
- Disconnect any hoses and wires in the area of the lifting eyes on the engine.
- Install the bracket (T10346) to the rear hole out of the three battery tray bolt holes.
- Use a M6 x 80 collar bolt or one of the battery tray bolts for this.
- Install the engine support bridge (10-222 A) and the engine support adapter (10-222 A/3) and the engine support feet (10-222 A/8) in front of the hood supports.
- Connect the spindle - arrow - to the left lifting eye on the engine.
- Then, connect the bracket (T10346) with the engine support bridge.
- Tension the engine/transmission assembly using the engine support bridge and the spindles.
- Loosen the left and right front wheel bolts.
- Lift the vehicle.
- Remove the front wheels.
- Remove the noise insulation.
- Remove the lower part of the left front wheel housing liner.
- Remove the left front level control system sensor (G78) from the control arm, if equipped.
- Remove the bracket from the starter.
- Remove the starter.
- Loosen the connections - arrows 1 and 2 - for the charge air hose and remove the hose.
- Remove the exhaust system suspended mount bolts - arrows - from the subframe.
- Disconnect the exhaust system at the double clamp - arrows -.
- Tie up the front exhaust pipe.
- If present, remove the exhaust system support - 1 - from the transmission - arrow - and remove the front exhaust pipe.
- Remove the pendulum support bolts from the transmission.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Remove the right side drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove the left and right drive axles from transmission flange shafts - A -.
- Secure the drive axles. Do not damage the protective coating when doing this.
- Remove the left and right coupling rods from the stabilizer bar.
- Remove the ball joint to control arm nuts - arrows - on the left and right sides.
- Secure the subframe before removing it.
- Remove the subframe with pendulum supports, stabilizer bar, and control arms.
- Remove the transmission mount - 2 - to transmission mount bracket bolts - arrows -.
- Turn the spindle - arrow - and lower the transmission.
Lower to approximately 60 mm - a -.
• When moving the engine/transmission assembly, be aware of the coolant hose between the engine and heater core. Do not overstretch them.
- Remove the transmission mount bracket - 1 - to transmission bolts - arrows -.
With a Metal Relay Lever:
- Remove the lock washer - arrow - from the relay lever - 1 - and then remove the relay lever.
With a Plastic Relay Lever:
- Remove the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.
Continuation for all
- Remove the transmission shift lever from the gear shift unit.
In some vehicles, the small flywheel cover plate - A - is difficult to access.
- In those vehicles first remove the coolant pipes - B - from the engine - arrows -.
• Do not open the cooling system in this process.
- Remove the small flywheel cover plate - A - - arrows -.
- Remove the lower engine/transmission bolts - 2 -.
• Loosen the engine/transmission bolt - 3 - and leave it in so that it is hand-tight.
To remove the transmission, the adjustment plate (3282/33) must be installed on the transmission support (3282).
- Install the transmission support (3282) to the engine/transmission jack (V.A.G 1383 A).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the support elements - A - as illustrated on the adjustment plate.
- Install the pins (3282/29) in place on the adjustment plate - C -.
- Position the engine-/gearbox jack (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the adjustment plate points in the direction of travel.
- Align the adjustment plate so that it is parallel to the transmission.
- Install the adapter (VW 771/40) in the transmission housing threaded hole as shown in illustration.
- Install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.
- Secure the transmission to the transmission support (3282) using a M6 x 80 bolt - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
- Remove the engine/transmission bolt - arrow -.
- Remove the last engine/transmission bolt (- C - in illustration N34-10359).
- Separate the transmission from the engine (alignment sleeves).
- Rotate the transmission upward near the differential by adjusting spindle on the transmission support (3282).
The right flange shaft - 1 - must be guided over the bolt flange on the cylinder block - 2 -.
- Tilt the transmission to the left by adjusting the spindles on the transmission support (3282).
- Carefully lower the transmission.
• Be careful of the steering gear - 3 - when lowering the transmission.
• Pay attention to the lines when lowering the transmission.