With the 3.0L TFSI Hybrid Engine
Transmission
Short Description
The transmission is removed individually in a downward direction in this vehicle. The engine and drive motor for electric operation remain in the vehicle.
Special tools, testers and auxiliary items required
• Bracket (30 - 211 A)
• Pry Lever-Rmv Outside Mirror (80-200)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Socket (T40058)
• Depth Gauge (VAS 6082)
• Engine Bung Set (VAS 6122)
• Gearbox Support (T40173)
• Step Ladder (VAS 5085)
Removing
There is high voltage in the high voltage system of the hybrid vehicle. Risk of electric shock! The following procedure requires work on the high voltage system. Disable the high voltage system.
• Removal of the transmission requires the step ladder (VAS 5085).
- Remove the engine cover.
- The procedure for disconnecting the batteries must be followed.
- Turn off the ignition and disconnect the battery ground cable.
- Remove the front and rear driveshafts.
- Remove the left and right catalytic converters.
- Remove the right heat shield from the transmission.
- Remove the bolts - 1 and 2 -, and remove the transmission fluid pipe from the transmission. Collect the leaking fluid.
- Seal the pipes using plugs from the engine bung set (VAS 6122).
- Disconnect the connectors - 1, 2 and 3 - from the transmission.
- Disconnect the connector - 1 - from the transmission fluid auxiliary hydraulic pump (V475) - 2 -.
- Disconnect the connector - 1 - from the multifunction transmission range switch (F125) - 2 -.
- Disconnect the selector lever cable - 1 - from selector shaft ball stud using the pry lever-rmv outside mirror (80-200) and remove the lock washer - 3 -.
• A removed lock washer may not be reinstalled. Always replace the lock washer.
• Do not bend or kink the selector lever cable.
• Ignore - 2 -.
- Assemble the socket (T40058) as follows.
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the socket.
- Counter hold the crankshaft using the socket (T40058) and an angled box end wrench, in order to loosen the drive plate bolts.
• Rotate the crankshaft only in engine rotation direction - arrow -.
- Remove the cap - 1 -. Remove the 3 bolts for the torque converter - arrow - through the opening in the transmission. Rotate the crankshaft 120° to access these bolts.
- Remove the transfer case.
The transmission support (VW 785/1B) must be removed again for the removal of the transfer case.
- Support the engine.
- Support the engine and transmission from above and release and remove the transmission support (VW 785/1B) via the spindle.
- Install the engine-/gearbox jack (V.A.G 1383 A) with the gearbox support (T40173) underneath the transmission and secure the transmission with a support strap if possible.
- Relieve the load on the engine and transmission at the top via the engine support bridge.
- Lower the transmission slightly using the engine-/gearbox jack (V.A.G 1383 A).
- Remove the transmission fluid pre-heater bolts - arrows - and pre-heater from the transmission.
- Remove right catalytic converter bracket bolts - arrows - and bracket - A -.
- Remove the breather hose - B - from the clip.
- Remove left catalytic converter bracket bolts - arrows - and bracket - A -.
• 2 transmission/drive motor bolts are removed at the same time as the left and right catalytic converter brackets.
- Support the engine at the top.
- Remove the remaining bolts - 1 through 10 - from the transmission.
- Remove the transmission from the electro-drive drive motor.
• During removal, it must be ensured that the torque converter does not slip out of the transmission.
- Remove the transmission in a downward direction using the engine-/gearbox jack (V.A.G 1383 A).
- After the removal of the transmission, use the bracket (30-211 A) to secure the torque converter from falling out.
Installing
Installation is performed in the reverse order of removal while observing the following:
In the case of dirty transmission fluid or before installing a replacement transmission, clean the transmission fluid cooler and pipes. Refer to => [ Transmission Fluid Pipes and Cooler, Cleaning ] ATF Pipes and Cooler, Cleaning.
Use a wire brush to clean the threads of bolts that were installed with locking fluid. Install the bolts using liquid locking fluid (AMV 185 101 A1).
Use a thread tap to clean all threaded holes containing self-locking bolts to remove any locking fluid residue. Otherwise the bolts could shear the next time they are removed.
- Always replace self-locking nuts and bolts.
- Reconnect all electrical connections, lines and hoses that were disconnected during removal.
- Prior to installation of the transmission, ensure that the torque converter is properly installed in the transmission. Refer to => [ Torque Converter, Installing ] Torque Converter, Installing.
- Check the installation dimension - a -. Refer to => [ Installed Dimension ] Torque Converter, Installing.
Prior to installation of the transmission to the drive motor, ensure that there are alignment sleeves - arrows - for centering the drive motor and transmission, if not then install them.
When connecting the drive motor and transmission, ensure that the stud bolts on the drive plate are flush with the converter bushings.
If the engine and transmission are connected with force when the converter is installed incorrectly, damage to the transmission and converter results.
- When installing the transmission to the drive motor, always make sure the converter is rotating freely and not jammed.
Install the transmission to drive motor bolts.
• Tightening specification: 30 Nm + 90° (1/4) additional turn. Replace the bolts.
- Install and tighten the 3 bolts for the torque converter - arrow - through the opening in the transmission. Rotate the crankshaft 120° in install these bolts.
• Tightening specification: 60 Nm.
- Install the cap - 1 -.
- Install the pre-heater and bolts - arrows - to the transmission.
- Remove the plugs and install the pipes to the transmission until they are seated.
- Install the bolts - 1 and 2 -. Refer to => [ Transmission Fluid Pipe Overview ] Transmission Fluid Pipe Overview.
- Carefully install the selector lever cable - 1 - to the selector shaft ball stud. Do not bend the selector shaft when doing this. Otherwise shifting can no longer be adjusted precisely.
- Install a new lock washer - 3 -.
- Check the selector lever cable setting, and adjust it, if necessary. Refer to => [ Selector Lever Cable, Checking and Adjusting ] Adjustments.
- Further installation is performed in reverse order of removal.
After installation, check the transmission fluid level and fill if necessary. Refer to => [ Transmission Fluid Level, Checking and Filling ] ATF Level, Checking and Filling.
