Removing
Transmission, Removing
- Before removing, print out the diagnostic protocol for the vehicle, if possible. Affix the protocol to the transmission before sending back the removed transmission in the usual way.
Short Description
The transmission is remove downward by itself. The engine remains in the vehicle.
From above:
Remove the battery, the battery tray, the air filter and the engine cover. The engine with transmission are then supported so that the transmission mount can be removed.
From underneath:
Remove the noise insulation. Remove the drive axles from the transmission and then remove the left drive axle. Lower the transmission using the transmission jack.
• The subframe is not removed.
Special tools, testers and auxiliary items required
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Socket SW 15 (V/175)
• Transmission Support (3282)
• Wedge Tool (T10161)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjusting Plate (3282/36)
• Engine Support Bridge (10-222 A)
• Hose Clamps up to 25 mm Dia. (3094)
• Tensioning Strap (T10038)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Engine Bung Set (VAS 6122)
• Crankshaft Adapter (T03003)
• Hose Clamps up to 40 (3093)
• Adapter (10-222 A/28) (Qty: 2)
• Adapter (10-222 A/28-1) (Qty: 2)
• Bracket with Spindle and Hook (10 - 222 A /10)
• Adapter (10-222 A /7)
• Spindle (10-222 A/11)
• Shackle (10-222 A/12)
• Hose Clip Pliers
Procedure
- Move the selector lever into the "P" position:
- Turn off the ignition and disconnect the battery ground cable.
- Remove the engine cover with air filter.
- Disconnect the hoses - arrows - and remove the intake tube from the throttle valve.
- Unclip and remove the transmission control module (J217) - 3 - from the bracket - 7 -.
- Disconnect the connector - 2 - from the transmission control module.
- Remove the bolts - 1 and 6 -.
- Move the bracket - 7 - and power steering fluid reservoir to the side. Pay attention to the electrical wires - 4 and 5 -.
The lines remain attached to the power steering fluid reservoir.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Disconnect the cable - arrows 1 - and then remove it from the cable bracket - arrow 2 -.
• Do not use pliers because the tabs on the cable mounting bracket could break off.
• Do not bend or kink the selector lever cable.
- Remove the selector lever cable - 3 - from the selector shaft lever using an open end wrench - 1 -.
- Disconnect the connector - 4 - from the multifunction transmission range switch (F125) and free up the electrical wire - 2 -.
- Remove the nut and the ground cable - 3 - from the transmission mount bracket stud bolt.
- Disconnect the electrical wires - 1 and 2 - from the starter and free them up.
- Remove the bracket - 1 - form the top starter bolt - arrow -.
- Remove the bolt from the top of the starter.
• Mark the transmission fluid cooler coolant hoses to prevent confusing them when installing them later.
- Clamp off the coolant hoses to the transmission fluid cooler using the hose clamps up to 25 mm dia. (3094) and hose clamps up to 40 mm (3093).
- Open the spring clamps - A - and pull the coolant hoses - B and C - off the cooler.
- Seal the coolant hoses and connections with plugs from the engine bung set (VAS 6122).
- Remove the upper transmission to engine bolts - arrows - using a 12 point swivel socket - A -.
- Remove the plenum chamber cover.
So that engine and transmission can be supported:
- Remove the wires - 1 - from the transport strap - 3 -.
- Remove the transport strap - 3 - from the engine - 2 - and pull it out of the lifting eye - arrow -.
- Attach one shackle (10-222 A/12) to this lifting eye.
- Remove the lock carrier trim.
- Remove the left and right lock carrier bracket bolts - arrows -.
- Remove the lower mounts from the adapters (10-222 A/28) and replace them with adapters (10-222 A/28-1).
- Install the adapters (10-222 A/28) with the adapters (10-222A /28-1) on the lock carrier and secure them in place to the threaded holes for the lock carrier bracket.
• Use the bolts in the adapters (10-222 A/28-1) for securing the adapters (10-222 A/28) and not the bolts for the lock carrier brackets.
• Bolt - arrows - tightening specification: 8 Nm.
A second technician will be needed when installing the engine support bridge (10-222 A) to the vehicle in order to prevent the engine support bridge from tipping over.
Install the engine support bridge as follows:
1. Adapter (10-222 A/31-2)
2. Moveable joint (T40091/3)
3. Adapter (10-222 A/31-1)
4. Moveable joint (T40093/4)
5. Square pipe (T40091/1)
6. Adapter (10-222 A/28) with adapters (10-222 A/28-1)
7. Bracket with spindle and hook (10 - 222 A /10)
- Slide the moveable joint (T40091/3) (- 2 -) onto the square pipe of the engine support bridge (10-222 A).
• The bolts for the moveable joints (T40091/3) (- 2 -) on the engine support bridge (10-222 A) face the front.
- Mount the engine support bridge (10-222 A) on the strut towers and have a second technician hold it to keep it from falling over.
- Push the left and right square pipes (T40091/1) (- 5 -) from the front, through the adapters (10-222 A/28) (- 6 -) and place the moveable joints (T40093/4) (- 4 -) on each side.
- Mount the bracket with spindle and hook (10-222 A/10) (- 7 -) onto the right square pipe (T40091/1).
- Slide the rail with holes (T40091/2) (- 9 -) with the mount (T40093/5) (- 10 -) into the moveable joint (T40093/4) (- 4 -).
1. Adapter (10-222 A/31-2)
2. Moveable joint (T40091/3)
3. Adapter (10-222 A/31-1)
4. Moveable joint (T40093/4)
5. Square pipe (T40091/1)
6. Adapter (10-222 A/28) with adapter (10-222 A/28-1)
7. Bracket with spindle and hook (10-222 A/10)
8. Adapter (10-222 A /7)
9. Slotted rail (T40091/2)
10. Mount (T40093/5)
11. Spindle (10-222 A/11)
12. Shackle (10-222 A/12)
- Install the locking pins into the rail with holes (T40091/2) (- 9 -) and secure them.
- Tighten the threaded connections on the engine support bridge (10-222 A) hand tight. Adjust the height of the engine support bridge parallel over the adapters (10-222 A/28).
- Use the adapter (10-222 A /7) (- 8 -) to lengthen the right bracket with spindle and hook (10-222 A/10) (- 7 -).
The hook on the adapter (10-222 A/7) points downward and will be engaged on the cylinder block later.
- Install the left spindle (10-222 A/11) (- 11 -) into the shackle (10-222 A/12) (- 12 -).
- Press the brake pedal and remove left drive axle bolt - arrow - (a second technician will be needed).
• From now on, do not let the vehicle touch the ground. Refer to "Drive Axle Twelve-Point Bolt, Loosening and Tightening".
- Raise the vehicle and remove the front wheels.
- Remove the noise insulation.
- Remove the left and right front wheel housing liners.
- Separate the exhaust system at the double clamp and remove the suspended mount bolts from the subframe.
- Remove the ball joint to control arm nuts - arrows - on both sides.
- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove both drive axles from the transmission.
- Remove the left drive axle from the vehicle.
- Lift the right drive axle as far as possible and then secure it.
- Disconnect the connectors - 1 and 2 - from the transmission.
- Remove the power steering line clamps - arrows - from the transmission.
- Remove the connector - 1 - from the bracket under the starter in the - direction of the arrow - and then disconnect it.
- Remove the bracket from the lower starter bolt.
- Remove the lower starter bolt and the starter.
- Turn the cap - 1 - in the - direction of the arrow - and remove it.
- Remove the 6 torque converter nuts - arrow - using the socket SW 15 (V/175).
- Rotate the engine in engine rotation direction - arrow - 60° further using the crankshaft adapter (T03003).
• If all six nuts are not removed from the torque converter, the torque converter will be pulled off from the engine when removing the transmission!
• Counter hold the vibration damper using the crankshaft adapter (T03003) when loosening the torque converter nuts.
- Remove the selector lever cable bracket nuts and bracket from the transmission.
- Remove the pendulum support, first remove bolt - A -, then remove bolts - B -.
- Engage the adapter (10-222 A/7) to the cylinder block.
Preload the bracket with spindle and hook (10-222 A/10) (- 7 -) one turn (more is not necessary).
- Support the engine and transmission using the spindle (10 - 222 A /11) (- 11 -). Do not lift yet.
- Remove the transmission mount to transmission mount bracket bolts - 2 - and the transmission mount bracket - A - to transmission mount bolts - 1 -.
- Remove the transmission bracket - A -. Lower the engine with transmission slightly, using the spindles on the engine support bridge (10-222 A).
Four turns should be sufficient.
- Remove the lower bolts between the engine and the transmission.
- For your safety, leave one bolt installed that is easily accessible.
- Install the transmission support (3282) onto the engine-/gearbox jack (V.A.G 1383 A).
- Place the adjusting plate (3282/36) on the transmission support (3282) (the adjusting plate only fits in one position).
- Align the arms of the transmission support so that they match up with the holes in the adjusting plate.
- Install support elements as shown on the adjusting plate.
- Move the engine-/gearbox jack (V.A.G 1383 A) and the transmission support (3282) under the transmission and support it.
- Secure the transmission to the transmission support (3282) using the nut - 1 - on the stud bolt.
- Remove the last transmission to engine bolt.
- While pressing the torque converter off the drive plate, separate the transmission from the engine.
- Guide the transmission past the power steering line and past the subframe when lowering it. Adjust the transmission support (3282) slightly, as necessary.
• Be careful not to damage the vacuum line between the vacuum pump and the brake booster when removing and installing the transmission.
• Be careful not to damage the connector on the front of the transmission during removal and installation, for example, by coming in contact with the power steering line. Replace the wiring harness in the transmission if the connector gets damaged. Refer to => [ Valve Body Overview ] Valve Body Overview.
• Be careful of the torque converter. It must be removed together with the transmission. Secure the torque converter with wire - A - to prevent it from falling out.
• The cable brackets must be replaced when installing a new transmission.
