Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Transmission Support (3282)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Tensioning Strap (T10038)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Spindle from Seal Installer Set - Rear Diff (3066) or a M8 x 105 Bolt
• Pin (3282/29)
• Adjustment Plate (3282/39)
• Thrust Piece (T10148)
• Adapter (10-222 A/28)
• Adapter (10-222 A /28-2)
• Grease for Clutch Plate Splines (G 000 100)
Perform the following
- Turn off the ignition and disconnect the battery ground cable.
- Remove the air filter with engine cover.
- Disconnect the hoses - arrows - and remove the intake hose from the throttle valve.
- Remove the bolts - 1 and 2 -.
- Lay the mount - 3 - and the power steering fluid reservoir aside and secure it.
The hoses remain attached to the power steering fluid reservoir.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Pull the locking mechanism for the selector cable all the way forward in the - direction of arrow 1 - and then unlock it to the left in the - direction of arrow 2 -.
- Push the relay lever forward in the - direction of the arrow 3 - and remove the selector cable.
- Remove the clip - arrow 1 - and remove the relay lever along with the cable retainer.
- Remove the lock washer - arrow 2 - and remove the shift cable from the transmission shift lever - A -.
- Remove the nut - arrow 3 - and then remove the transmission shift lever - A -.
- Remove the cable bracket bolts - arrows - and bracket - 1 - from the transmission.
- Secure the cable bracket and cable out of the way.
- Free up the wire - 2 - from the bracket - 1 -.
- Remove the bolt - 3 - and then the bracket.
- Remove the transmission support bolts - A arrows -.
- Remove the clutch slave cylinder bolts - B arrows - and lay aside, secure with wire, do not open the hydraulic system.
Do not press the clutch pedal anymore.
- Disconnect the connector - arrow 1 - from the backup lamp switch (F4).
- Remove the connector - arrow 2 - and wire - arrow 3 - from the starter.
- Remove the ground cable from the bolt on the top of the starter.
- Remove the upper bolt from the starter.
- From above, remove the accessible transmission to engine bolts - 1 and 2 -.
- Remove the plenum chamber cover.
So that engine and transmission can be supported:
- Remove the transport strap - arrow B - and pull it out of the lifting eye - arrow A -.
- Install 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 on the adapters (10-222 A/28) and replace them with adapters (10-222 A/28-1).
- Mount the adapters (10-222 A/28) with adapters (10-222 A/28-1) on the left and right lock carrier brackets and secure them in the threaded holes for the lock carrier brackets - arrows -.
• Use the bolts for the adapters (10-222 A/28-1) for securing the adapter (10-222 A/28) and not the bolts for the lock carrier bracket.
• Bolt - arrows - tightening specification: 8 Nm.
A second technician will be needed for 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 adapter (10-222 A/28-1)
7. Bracket with spindle and hook (10-222 A/10)
- Install the moveable joints (T40091/3) (- 2 -) onto the engine support bridge (10-222 A) square pipe.
• The moveable joint (T40091/3) (- 2 -) bolts, when installed on the engine support bridge (10-222 A) face the direction of travel.
- Install the engine support bridge (10-222 A) on the strut towers and have a second technician hold it to keep it from falling over.
- Install the square pipes (T40091/1) (- 5 -) on the left and right sides, through the adapters (10-222 A/28) (- 6 -) and install the moveable joints (T40093/4) (- 4 -) onto the square pipe.
- Install the bracket with spindle and hook (10-222 A/10) (- 7 -) to the right side square pipe (T40091/1).
- Install 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. Rail with holes (T40091/2)
10. Mount (T40093/5)
11. Spindle (10-222 A/11)
12. Shackle (10-222 A/12)
- Install the locking pin into the rail with holes (T40091/2) (- 9 -) and secure it with the cotter pin.
- Tighten all threaded connections on the engine support bridge (10-222 A) hand tight. Adjust the height of the engine support bridge parallel over the adapter (10-222 A/28).
- Lengthen the right bracket with spindle and hook (10-222 A/10) (- 7 -) with adapter (10-222 A/7) (- 8 -).
The hook on the adapter (10-222 A/7) faces downward and will be attached to the cylinder block later.
- Attach the left spindle (10-222 A/11) (- 11 -) in the shackle (10-222 A/12) (- 12 -).
- Raise the vehicle and remove the left front wheel.
- Remove the noise insulation.
- Remove the left front wheel housing liner..
- Remove the power steering line brackets - arrows - from the transmission.
- Remove the nut - arrow - and then remove the wire bracket.
- Remove the lower bolt from the starter and then remove the starter.
- Separate the front exhaust pipe with catalytic converter at the clamping sleeve and remove the suspended mount bolts - arrows - from the subframe.
- Tie up the front exhaust pipe.
• Do not bend the coupling element in the front exhaust pipe more than 10° or it will be damaged.
- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove left and right drive axles from the transmission flange shafts.
- Tie up the left and right drive axles with a cable tie or with a tensioning strap (T10038).
Do not damage the surface of the drive axle.
- Remove the right flange shaft bolt - arrow - in order to loosen the bolt, install two bolts in the flange and then counter hold with a pry bar.
- Remove the flange shaft.
• Check the seal for leaks before removing the flange shaft. If the seal has leaks, replace it when installing.
- Install the spindle - A - from the seal installer set - rear diff (3066) into the threaded piece on the differential.
- Install the thrust piece (T10148) and secure it with the nut - B -.
• The thrust piece (T10148) should protect the right seal and the transmission from dirt.
• A M8 x 105 mm bolt may be installed by hand into the differential threaded piece instead of a the spindle - A -.
- Remove the pendulum support, first remove the bolt - A -, then the 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.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
- Angle the engine/transmission subassembly by lowering it using the spindles on the engine support bridge (10-222 A).
• The transmission mount bracket bolts - arrows - must be accessible.
- Remove the transmission mount bracket - A - to transmission bolts - arrows -.
To remove the transmission, the adjustment plate (3282/39) must be installed on the transmission support (3282).
- Install the transmission support (3282) onto the engine-/gearbox jack (V.A.G 1383A).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the mounting elements - A and C -, onto the adjustment plate, as illustrated.
- Position the engine-/gearbox jack 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 and secure the safety support to the transmission.
- Then, install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.
- Support the transmission from underneath using the engine-/transmission jack (V.A.G 1383 A).
- Remove the lower engine/transmission bolts.
- Remove the transmission from the alignment sleeves and carefully move it toward the subframe.
- Tip the transmission over the adjusting spindle for the transmission support (3282) in the- direction of the arrow -.
- Push the engine forward slightly with help from a 2nd technician.
- Carefully lower the transmission using the engine-/transmission jack (V.A.G 1383 A) , while making sure that the right flange shaft seal - 1 - is guided through without any damage to the pressure plate - arrow -.
- Guide the left flange shaft - B - past the subframe - arrow - as illustrated. Move the engine-/gearbox jack with the transmission to the front.
- When lowering, change the position of the transmission using the spindles on the transmission support (3282).
• Guide the transmission past the power steering line and past the subframe when lowering it.
- Reinsert the right flange shaft if necessary and tighten the bolt - arrow - to 25 Nm.
