With A Gas Engine
Transmission, Removing
Short Description
The transmission is remove downward by itself.
"From above":
The battery, air filter housing and starter are removed. The steering gear wiring harness is disconnected and freed up. This way it can be lowered together with the subframe and steering gear. The engine and transmission are supported before the transmission mount bracket is removed.
"From underneath":
The subframe, with the pendulum support, the steering gear and both lower control arms are removed together.
Both drive axles are disconnected from the transmission and remain inside the wheel bearing housings. Occasionally they will be moved to the side, but they still remain on the vehicle.
Special tools, testers and auxiliary items required
• Transmission Support (3282)
• Adjustment Plate (3282/42A)
• Pin (3282/29)
• 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)
• Engine Support Bridge (10-222 A)
• Hose Clamps Up to 25 mm Dia. (3094)
• Hose Clamps Up to 40 mm (3093)
• Tensioning Strap (T10038)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Engine Bung Set (VAS 6122)
• Bracket (T10338)
- Move the selector lever into the "P" position.
- Turn off the ignition and disconnect the battery ground cable.
- Remove the air filter housing.
- Remove the air filter housing bracket.
- Remove the selector lever cable from the transmission - arrows -.
• Use pliers to remove the lock washers. Do not use a sharp edged tool. Otherwise the selector lever cable could get damaged.
• Remove the cable bracket - 2 - from the transmission, if necessary. Remove the bolts - 1 - and the lock washer - 3 -.
• Replace the bolts - 1 - and lock washer - 3 -.
• Bolt - 1 - tightening specification, see - item 7 - in the => [ Selector Mechanism Overview ] Selector Mechanism Overview.
Remove the cable from the cable bracket. Do not bend the cable.
You can also slide the cable back slightly from the cable bracket and remove it later when lowering the transmission. Watch the cable when lowering the transmission.
Later, during installation, only install new lock washers after you have checked and adjusted the cable. Refer to => [ Selector Lever Cable, Adjusting ] Adjustments.
- Place lint free cloths on the transmission oil cooler and transmission to absorb leaking coolant.
• When the engine is warm, the cooling system is under pressure.
• Cover the cap on the expansion tank with a cloth and open it carefully before removing the coolant hoses.
- Clamp off the coolant hoses using the hose clamps up to 25 mm dia. (3093) or hose clamps up to 40 mm (3094) and remove the hoses from the transmission oil cooler.
- Seal the transmission oil cooler connections with plugs from the engine bung set (VAS 6122).
- Remove the lower coolant pipe bolt - arrow - - A - and upper coolant pipe bolt - B -.
- Remove the starter - A -.
Remove the lower starter bolt first.
Risk of destroying the Mechatronic unit with static electricity.
• Do not touch the contacts in the Mechatronic unit connector with hands.
- To discharge any static electricity, touch a ground with hand (without wearing a glove). Refer to => [ Electrical Component Location Overview ] 02E Transmission (Direct Shift Gearbox).
- Release and remove the connector - 1 - for the Mechatronic unit by turning it in the direction of the starter.
- Remove all upper engine/transmission bolts.
These tools are suitable for this.
Special tools, testers and auxiliary items required
• Multi-point socket (T10035)
• Socket, multi-point bit XZN 14 (T10061)
• Bits (T10099)
• Insert tool 18 mm (T10179)
- Disconnect any hoses and cables in the area of the lifting eyes on the engine.
- Install the bracket (T10338) in the open threaded hole - arrow - on the left rear of the engine.
- Remove the plenum chamber cover.
- Remove the bolts- arrows - from the left and right side lock carrier brackets.
- Remove the lower mounts from the adapters (10-222 A/28) and replace them with the adapters (10-222 A/28-2).
- Mount the adapters (10-222 A/28) with adapters (10-222 A/28-2) onto the lock carrier and secure them to the threaded holes for the lock carrier bracket using the bolts - arrows -.
• Use the bolts - arrows - from the adapters (10-222 A/28-2) for securing the adapters (10-222 A/28) and not the bolts for the lock carrier bracket.
• Bolt 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/28-2)
7. Bracket with spindle and hook (10-222 A/10)
8. The bracket (T10338) is installed on the engine.
- Slide the moveable joints (T40091/3) (- 2 -) onto the square pipe from the engine support bridge (10-222 A).
• The bolts for the moveable joints (T40091/3) (- 2 -) on the square pipe 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 install the moveable joints (T40093/4) (- 4 -) on each pipe.
- Mount the bracket with spindle and hook (10-222 A/10) (- 7 -) on the left side square pipe (T40091/1).
- Connect the bracket with spindle and hook (10-222 A/10) (- 7 -) to the bracket (T10338).
- Slide the rail with holes (T40091/2) (- 9 -) with the mount (T40093/5) (- 10 -) into the moveable joints (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/28-2)
7. Bracket with spindle and hook (10-222 A/10)
8. Bracket (T10338)
9. Rail with holes (T40091/2)
10. Mount (T40093/5)
11. Spindle (10-222 A/11)
- Install the locking pins into the rail with holes (T40091/2) (- 9 -) and secure them.
- Tighten the threaded connections on the engine support bridge hand tight. Adjust the height of the engine support bridge parallel over the adapters (10-222 A/28).
- Tension the engine/transmission subassembly using the bracket with spindle and hook (10-222 A/10) (- 7 -) and spindle (10-222 A/11) (- 11 -) slightly, but do not lift it.
- Loosen the left and right front wheel bolts.
- Raise the vehicle and remove the front wheels.
- Remove the noise insulation.
- Remove the left and right front wheel housing liners..
- Remove the bolt - 1 - for the lower coolant pipe - 2 - on the engine and tie up the coolant pipe.
- Remove the engine to transmission bolts - 3 through 5 -.
- Free up the front wire - 6 - on the transmission.
- Remove the electrical wires from the bracket, remove the nuts - arrows - (two M6 nuts) and the bracket from the transmission front cover.
- Route the wires near the transmission front cover upward and secure them.
- Disconnect the connector - 1 - from the oil level thermal sensor.
- Disconnect the exhaust system at the clamping sleeve and remove the exhaust system 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 the drive axles from the transmission.
- Tie the right drive axle as high up as possible.
- Move the left drive axle to the rear and secure it. Be careful not to damage the surface protection.
- Remove the subframe with steering gear.
- Remove the ground wire from the bolt for the transmission mount bracket.
- Remove the transmission mount to transmission mount bracket bolts - 2 - and the transmission mount bracket to transmission bolts - 1 -.
- Lower the engine/transmission approximately 50 mm - a - using the spindles on the engine support bridge (10-222 A).
• Observe the vacuum line between the engine and the brake booster.
- Remove the transmission mount bracket - arrow -.
To remove the transmission he adjustment plate (3282/42A) must be installed on the transmission support (3282) and both must be installed on the engine-/gearbox 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 (3282/42A).
- Install the support elements on the adjustment plate (3282/42 A) as illustrated.
- Place the engine-/gearbox jack (V.A.G 1383 A) under the vehicle.
• The arrow symbol on the adjustment plate (3282/42 A) points in the direction of travel.
- Align the transmission support (3282) so that it is parallel to the transmission.
- Screw the pins (3282/29) into the transmission.
- Secure both support elements to the transmission as illustrated.
• Deviating from the illustration of the adjustment plate, the front transmission support is illustrated mounted to the transmission with an M10 x 50 mm bolt - arrow -. Install a M12 bolt between the mount and the transmission housing.
• An All Wheel Drive (AWD) Direct Shift Gearbox (DSG(R)) is shown in the illustration. The mounting elements on a Front Wheel Drive (FWD) are identical.
• Deviating from the illustration of the adjusting plate the front transmission support is illustrated mounted to the transmission with an M10 x 50 mm bolt - arrow -. Install a M12 bolt between the mount and the transmission housing.
• DSG transmission 02E "AWD" is shown in the illustration. The mounting elements on the "FWD" are identical.
- Lift the engine-/gearbox jack (V.A.G 1383 A) to support the transmission from underneath.
The transmission is disconnected from the engine in this position.
- Remove the remaining engine/transmission bolts - 8 through 10 -.
- Remove transmission from engine while being careful of selector lever cable and lower the transmission.
• Pay attention to the wires when lowering the transmission.
Transport the transmission and secure it to the assembly stand. Refer to => [ Transmission, Transporting ] Transmission, Transporting.
Install the transmission. Refer to => [ Transmission, Installing ] Transmission, Installing.