Removal and Replacement
Transmission
Removing
- Before beginning with removal, if possible print out a diagnosis log. Before sending back removed transmission in the usual manner, secure log to transmission.
Brief description
The transmission is removed downwards separately. The engine remains in vehicle.
Battery tray, air filter and engine cover are removed from above. Engine and transmission must then be supported so that left assembly mounting can be removed.
Noise insulation is removed and drive axles are pressed off from below. Transmission is lowered using transmission jack.
• The subframe is not to be removed.
Special tools, testers and auxiliary items required
• Engine/transmission jack (V.A.G 1383 A)
• Torque wrench (V.A.G 1332)
• Transmission support (3282)
• Adjustment plate (3282 /36)
• Insert (V/175)
• Wedge (T10161)
• Support bracket (10 - 222 A)
• Adapter (10 - 222 A /8)
• Adapter (10 - 222 A /3)
• Hook (10 - 222 A /10)
• Shackle (10 - 222 A /12)
• Adapter (10 - 222 A /7)
• Socket key (T03003)
• Hose clamp pliers (V.A.G 1921)
Removing
- Before beginning with removal, if possible, print out a diagnosis log. Before sending back removed transmission in the usual manner, secure log to transmission.
- Move selector lever to position P position.
- Raise vehicle. All 4 supports of lifting platform must be at same height.
- Depress brake pedal to remove bolt for left drive axle - arrow - (second technician required).
• After this, do not set vehicle on the ground any more
- Remove air filter with engine cover.
- Pull off hoses - arrows - and remove intake hose from throttle valve unit.
- Remove battery and battery tray
- Release selector lever cable from transmission by hand - 1 - and pull out of cable support bracket - 2 -.
Work with care to avoid bending cable. Do not use pliers, or retaining tabs on cable support bracket may break off.
- Then pry cable off ball head using wrench - 2 -.
- Disconnect electrical connections to transmission and starter.
• Multi-Function Transmission Range (TR) Switch
• Starter motor
• Ground (GND) cable to bracket
- Remove wiring retainer - 1 - from starter bolt - 1 -.
- Remove upper starter motor bolt.
- Remove upper engine/transmission connecting bolts.
To support engine and transmission:
- Remove wiring - 1 - from transportation bracket - 3 -.
- Remove transportation bracket - 3 - from engine - 2 - and pull out of eye - arrow -.
- Attach a shackle (10 - 222 A /12) in this eye.
- Set up support device (10 - 222 A).
- Extend right hook (10 - 222 A /10) using adapter (10 - 222 A /7).
The hook faces downwards and will later be hooked into engine block.
- Remove noise insulation tray.
- Remove lower part of left wheel housing liner.
- Remove heat shield above right drive axle.
- Remove - nuts - from lower suspension links on both sides.
- Press both drive axles out of transmission.
- Remove left drive axle.
- Raise right axle as far as possible and secure in this position.
Plastic cable ties are a very good choice because surface protection of shaft must not be damaged.
- Now pull electrical connectors - 1 - and - 2 - off transmission.
- Pull connector beneath starter - 1 - out of retainer and separate.
- Remove retainer from lower starter bolt.
- Remove lower starter bolt and remove starter.
- Remove pendulum support - A - first and then - B -.
- Drain coolant.
- Turn cap - 1 - in direction of - arrow - and remove.
- Remove six - torque converter nuts - using insert (V/175). Turn crankshaft 60° using Socket key (T03003) for each nut in turn.
• Continue turning the engine carefully!
- Hook adapter (10 - 222 A /7) into engine block.
- Pull coolant hoses off ATF cooler.
Tighten right spindle one turn (more is not necessary).
- Support engine and transmission with left spindle. Do not raise.
- Remove bracket - A -.
- Now remove assembly mounting bracket. To do this, lower engine and transmission slightly via left spindle of support bracket (10 - 222 A).
Six turns are sufficient.
- Remove lower engine/transmission connecting bolts.
- Leave an easily accessible bolt in for safety purposes.
- Before you now remove final connecting bolt, support transmission with engine/transmission jack (V.A.G 1383 A), transmission support (3282) and adjustment plate (3282 /36).
- Only now is the final bolt removed.
- Carefully push transmission off engine.
• Observe torque converter. It must be removed together with transmission.
Installing
- Check whether dowel sleeves are pressed into engine flange.
- Check seating of intermediate plate between engine and transmission. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly engaged behind the drive plate.
Continue installation in reverse order of removal.
The engine and transmission should be mounted tension-free in assembly mounting. The correct procedure is described in (Gasoline engines)10 Removal and Installation.
- Replace all bolts of left assembly mounting.
- First install all bolts by hand.
During installation, first bolt bracket to transmission with 40 Nm plus an additional 90° torque.
When two bracket bolts are tightened to vehicle, a screwdriver may be inserted between two bolts to adjust to previous seating. These two larger bolts are tightened to 60 Nm plus an additional 90°.
Torque settings, transmission to engine --> [ Specifications ] Specifications
- Adjust selector lever cable --> [ Selector Lever Cable, Adjusting ] Adjustments.
- After installing, check ATF level --> [ ATF Level, Checking and Filling ] Service and Repair.
- Carry out basic settings. To do this
- Connect vehicle diagnosis, testing and information system (VAS 5051) and then select "Perform basic settings " under Guided Functions.