Transmission, Removing 09D

Special tools and workshop equipment required

Scissor Lift Table VAS 6131
Basic Set VAS 6131/1 VAS 6131/1
Counterhold Tool Touareg V10T10172
Counter Hold Tool 3435
Shop Crane VAS 6100
Lifting Tackle 3033

Brief Description

The automatic transmission -09D- is removed together with the engine, front final drive and transfer case -1-. The procedure for this is described in the engine section.

For all engine variations of the Touareg, it is advisable to remove the lower engine/transmission bolts, even before the removal of the gear set. When possible, the torque converter bolts should also be removed early on. This applies when removing, as well as when installing the transmission.

There are two variations for separating the engine and transmission from each other while on the VAS 6131:

First Variation

The automatic transmission -09D- and the transfer case -1- remain fastened to each other. They can be removed from engine together, for example, for removing and installing the torque converter.

For this, only disconnect the front driveshaft -2- from the transfer case. This way, when separating, the engine can be placed on one side of the VAS 6131 and both the transmission and transfer case on the other side.

Second Variation

First, the transfer case is removed from the table, then the automatic transmission. This way, repairs can be performed on the automatic transmission. For this, first the front driveshaft must be loosened on both sides, the transfer case -1- must be removed from the table. Then, the automatic transmission is removed from the engine and the table, if necessary.

The second variation is described here.

Fig 1: Drivetrain Guide, Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Transfer Case
- Precautions and tightening specifications for servicing the transfer case. Refer to Removal and Installation .
Driveshaft, Front and Rear
Rear Final Drive
Front Final Drive

Removing

-- For all engine variations, it is advisable to remove the lower engine/transmission bolts, even before the removal of the gear set.

When possible, the torque converter bolts should also be removed early on.

-- Remove the engine and transmission. Refer to one of the following:

Gas engines, refer to [For engine(s) BMX, BAA] Removal and Installation or to [For engine(s) AXQ] Removal and Installation or to [For engine(s) BHK] Removal and Installation or to [For engine(s) BAR] Removal and Installation .

Diesel engines, refer to [For engine(s) BWF, BKW] Removal and Installation .

With a V6 or V8 Gas Engine

Fig 2: Identifying Torque Converter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the starter. Refer to Removal and Installation .

-- Remove the torque converter to drive plate bolts.

With a V10 TDI Diesel Engine

Fig 3: Identifying Torque Converter Fasteners

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the starter cable until the bolt -arrow- can be removed. Refer to Removal and Installation .

On these models, the torque converter bolts and the lower engine/transmission bolts should be installed with the gear set mounted.

With a V6 TDI Diesel Engine

-- Remove the starter far enough so that the torque converter bolts can be removed.

Continuation for All Vehicles

Fig 4: Transmission Supported With VAS 6131/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Make sure that at least two VAS 6131/1 on the lifting table are placed under the oil pan as support for the automatic transmission.

-- Remove the driveshaft between transfer case and front final drive.

-- To counter hold the driveshaft, T10172 can be used.

-- 3435 with two bolts up to size M10 is also recommended.

Fig 5: Identifying Counter-Holder 3435 With Two Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the transfer case with a shop crane.

Fig 6: Attaching Engine Sling 2024A As Follows To Lifting Eyes Of Transfer Case And Transport With Workshop Crane

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transfer case and set aside. Refer to Removal and Installation .

With a V6 TDI Diesel Engine

Fig 7: Catalytic Converter And Particle Filter, Coolant Lines, Speed Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the catalytic converter and particle filter -1- from the turbocharger.

Always replace the nuts for turbocharger.

-- Remove the coolant lines -2- from the torque converter housing (2 bolts).

-- Remove the speed sensor -3-.

-- Disconnect the Automatic Transmission Fluid (ATF) lines.

-- If still attached, remove the left heat shield from the transmission.

Later, when separating the V6 TDI engine from the transmission, prevent the engine from tipping downward.

-- Therefore, support the engine now using VAS 6100 and 3033. Guide the shop crane to the table from the side.

Fig 8: Supporting Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If a second crane is not available, separate the engine and transmission and then support the engine with available materials.

Continuation for All Vehicles

Fig 9: Supporting Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before the engine and transmission are separated from each other, secure the engine from tipping over.

In the case of the V6 TDI diesel engine, this will be shown here once again.

-- If a second crane is not available, separate the engine and transmission and then support the engine with available materials.

-- Transport the transmission with a shop crane. Refer to TRANSMISSION, TRANSPORTING .

-- Loosen the ATF lines.

-- Remove all bolts for the engine/transmission.

-- Carefully separate the transmission from the engine.

-- Make sure that the converter is also pressed from drive plate with the transmission.