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Home >> Volkswagen >> 2006 >> Passat Value Edition, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Controls, Housing Transmission 09M) >> 37 Controls, Housing >> Removal And Installation >> Transmission >> Removing
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Removal And Installation: Transmission: Removing

WARNING: This page is about a different variant/trim than selected.

Short Description: 

-- Prior to removal, print out a diagnostic protocol. Return the removed transmission with the protocol.

The transmission is remove downward by itself. The engine remains in the vehicle.

Remove the air filter housing and engine cover >>from the top<<. The engine and transmission are supported and it is possible to remove the transmission mount.

Remove the noise insulation and transmission fluid lines >>from underneath<<. This detaches the drive axles and the transmission jack can lower the transmission.

NOTE:

The subframe is not removed.

Special tools and workshop equipment required 

Removal 

-- Lift the vehicle.

-- Move the selector lever into the "P" position.

-- Turn off the ignition and disconnect the ground cable from the battery. Refer to Removal and Installation .

-- Remove the air filter housing.

-- Disconnect the selector lever cable from the transmission -1- and pull it out of the bracket -2-.

Fig 1: Identifying Cable Disengaged And Removed From Mounting Bracket
GWWN37-0324Courtesy of VOLKSWAGEN UNITED STATES, INC.

Be careful not to bend the cable. Do not use pliers, otherwise the retainers on the cable bracket may break off.

-- Pry the cable off the selector shaft lever -3- ball stud using an open end wrench -2-.

Fig 2: Identifying Selector Lever Cable, Lever/Selector Shaft And 10mm Open-End Wrench
GWWA37-0577Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the cable from the bracket on the transmission.

Fig 3: Identifying Selector Lever Cable Retainer And Bolts
GWWN37-10203Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the following connectors from the transmission and starter.

-- Remove the coolant lines -1 and 2- from the engine and disengage the wiring harness.

Fig 4: Identifying Coolant Lines At Engine
GWWN37-10314Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the engine support bridge 10-222 A.

Fig 5: Identifying Engine Support Bridge -10-222 A- Installed
GWWN37-10313Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Attach it to the engine/transmission. Do not lift yet.

Fig 6: Identifying Hanging Engine/Transmission
GWWN37-10312Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the transmission mount to transmission mount bracket bolts -1-.

Fig 7: Identifying Engine Support Bracket Bolts
GWWN37-10309Courtesy of VOLKSWAGEN UNITED STATES, INC.
WARNING:

Steam may escape when opening the coolant expansion tank. Wear protective eyewear and clothing protection to prevent eye injury and scalding. Cover the cap on the expansion tank with a cloth and open it carefully.

-- Open the cap on the coolant expansion tank.

-- Install the hose clamps up to 25 mm dia. -3094- on the hoses and remove the hoses from the transmission fluid cooler.

Fig 8: Identifying Hose Clamps Position On ATF Cooler Hoses
GWWN37-10120Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove both upper engine/transmission bolts.

-- Press the brake pedal and remove the left drive axle bolt -arrow-. A second technician will be needed.

Fig 9: Identifying Left Drive Axle Bolt
GWWN37-0095Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

Do not let the vehicle rest on the floor. Refer to Removal and Installation .

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the right drive axle heat shield from the engine, if equipped.

-- Disconnect the both connectors from the transmission.

-- Remove the lower section of the left wheel housing liner.

-- Remove the pendulum support, first remove the bolt -A-, and then the bolts -B-.

Fig 10: Identifying Pendulum Support And Bolts
GWWN34-10007Courtesy of VOLKSWAGEN UNITED STATES, INC.

(When installing again, first tighten the bolts -B-, and then the bolt -A-) Tightening specifications, refer to Specifications .

-- Remove the ball joint to lower control arm nuts -arrows- on both the left and right sides of the vehicle.

Fig 11: Identifying Lower Control Arm And Bolts
GWWN40-10005Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ball joint to control arm nut tightening specifications, refer to Specifications .

-- Remove both drive axles from the transmission. Refer to: Removal and Installation .

-- Remove the left drive axle

-- Secure the right drive axle as high as possible to the strut.

Fig 12: Identifying Ratchet Strap
GWWN37-10373Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the lower engine/transmission bolts.

-- Leave one easily accessible bolt for safety.

-- Start with both lower bolts.

-- Remove the six torque converter nuts -arrow- using the socket -SW15V/175-. Counter hold the starter ring gear with a screwdriver.

Fig 13: Identifying Torque Converter Nuts
GWWN37-10304Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Clamp off the hoses for the transmission fluid pipes -2- using the hose clamps up to 25 mm dia. -3094-.

Fig 14: Identifying ATF Lines
GWWN37-10308Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the bolt -1- and then pull the pipes -2- from the transmission.

-- Seal off the pipes and transmission with clean plugs.

-- Align the transmission support -3282- with adjusting plate -3282/56-.

-- Support the transmission with the engine- / gearbox jack -V.A.G 1383 A- and the transmission support -3282-, do not raise yet.

-- Remove the last bolt.

-- Separate the transmission from the engine.

NOTE:

Pay attention to the torque converter. It must be removed together with the transmission.

-- The following bolts must be replaced when installing a new transmission.

Fig 15: Identifying Mounting Bracket And Bracket For Selector Lever Cable
GWWN37-10294Courtesy of VOLKSWAGEN UNITED STATES, INC.


Short Description: 

-- Prior to removal, print out a diagnostic protocol. Return the removed transmission with the protocol.

The transmission is remove downward by itself. The engine remains in the vehicle.

Remove the battery case, air filter housing and engine cover >>from the top<<. Both the engine and the transmission are supported and it is possible to remove the transmission mount.

After removing the bevel box, support the transmission, remove the last bolt securing the engine and transmission and lower the transmission.

NOTE:

The subframe is not removed.

Special tools and workshop equipment required 

Removing 

-- Lift the vehicle, all 4 lift points of the hoist must be at the same height.

-- Turn the steering to the center position.

-- Remove the ignition key and engage the steering wheel lock.

-- Move the selector lever into the "P" position.

-- Loosen both drive axle bolts -arrows-.

Fig 1: Identifying Left Drive Axle Bolt
GWWN37-0095Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

Do not place the vehicle on the floor after loosening the bolts.

-- Remove both front wheels.

NOTE:

To make it possible to rotate the driveshaft later so it can be loosened:

-- Move the selector lever into the "N" position.

-- Remove the ignition key and engage the steering wheel lock.

-- Disconnect the battery. Refer to Removal and Installation .

-- Remove the air filter housing and bracket underneath it. Refer to AIR FILTER HOUSING OVERVIEW for BLV engines or AIR FILTER HOUSING for CCTA .

-- Disconnect all electrical connections to the transmission and starter that are >>easily accessible from above<<.

-- Disconnect the selector lever cable from the transmission -1- and pull it out of the bracket -2-.

Fig 2: Identifying Cable Disengaged And Removed From Mounting Bracket
GWWN37-0324Courtesy of VOLKSWAGEN UNITED STATES, INC.

Be careful not to bend the cable. Do not use pliers, otherwise the retainers on the cable bracket may break off.

-- Pry the cable off the selector shaft lever -3- ball head using a open end wrench -2-.

Fig 3: Identifying Selector Lever Cable, Lever/Selector Shaft And 10mm Open-End Wrench
GWWA37-0577Courtesy of VOLKSWAGEN UNITED STATES, INC.
WARNING:

Steam may escape when opening the coolant expansion tank. Wear protective eyewear and clothing protection to prevent eye injury and scalding. Cover the cap on the expansion tank with a cloth and open it carefully.

-- Open the cap on the coolant expansion tank.

-- Clamp off the coolant hoses using the hose clamps up to 25 mm dia. -3094- and remove the hoses.

Fig 4: Identifying Hose Clamps Position On ATF Cooler Hoses
GWWN37-10120Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the coolant lines -1 and 2- from the engine and disengage the wiring harness.

Fig 5: Identifying Coolant Lines At Engine
GWWN37-10314Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Then, remove all upper engine/transmission bolts.

It is advisable to complete the work >>under<< the vehicle now. This prevents the weight of the engine from weighing on the engine support bridge for a >>long period of time<<.

-- Remove the noise insulation and the lower section of the left front wheel housing liner. Refer to Removal and Installation .

-- Remove the ball joint to lower control arm nuts -arrows- on both sides of the vehicle.

Fig 6: Identifying Lower Control Arm And Bolts
GWWN40-10005Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect connector from the left front level control system sensor -G78-.

-- Press both drive axles off the transmission and remove them.

-- Remove the pendulum support, first remove the bolt -A-, and then the bolts -B-.

Fig 7: Identifying Pendulum Support And Bolts
GWWN34-10007Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the right drive axle heat shield bolts -arrows- and heat shield.

Fig 8: Identifying Right Driveshaft Heat Shield And Bevel Box
GWWA39-0277Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Mark the position of the driveshaft flexible disc to the bevel box output flange.

-- Remove the rear flexible disc bolts -arrows- from the bevel box.

Fig 9: Identifying Flexible Disc Bolts On Bevel Box
GWWA10-10247Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Counter hold the rear final drive to loosen and tighten the driveshaft.

Fig 10: Identifying Counter Hold Tool -T10172-
GWWN37-10410Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

To loosen the next bolt, rotate the driveshaft by turning the rear wheels.

The seal -arrow- in the driveshaft must not be damaged.

Fig 11: Identifying Sealing Ring In Driveshaft Flange
GWWV39-1817Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Clamp the assembly tool -T10071- with a cloth. This protects the seal.

Fig 12: Identifying Assembly Fixture T10071 Clamped With Cloth
GWWN34-10726Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the bracket -A- from between the engine block and bevel box.

Fig 13: Identifying Tightening Sequence
GWWN37-10320Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the bevel box to transmission upper bolts -arrows-.

Fig 14: Identifying Bevel Box To Transmission Top Bolts
GWWN34-11003Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the bevel box to transmission lower bolts -arrows-.

Fig 15: Identifying Lower Bevel Box Mounting Bolts At Manual Transmission
GWWN34-10500Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the connector -1- from the oil level thermal sensor -G266-.

Fig 16: Identifying Wooden Block
GWWN39-10324Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Press the engine and transmission forward by hand and secure in this position with a suitable block of wood -A-.

-- Carefully press the bevel box off the transmission and remove it downward.

-- Remove the plugs -arrow-.

Fig 17: Locating Plugs
GWWN37-10322Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the six torque converter bolts through the opening using the socket -SW15V/175-. Counter hold the starter ring gear with a screwdriver.

-- Remove all easily accessible bolts between the engine and transmission except for one.

-- Disconnect the two connectors on the transmission. They are accessible from below.

-- Clamp off the hose for the transmission fluid pipes -2- using the hose clamps up to 25 mm dia. -3094-.

-- Remove the bolt -1- and then pull the pipes -2- from the transmission.

Fig 18: Identifying ATF Lines
GWWN37-10308Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Seal off the pipes and transmission with clean plugs.

-- To ensure the rear engine support bridge spindle has sufficient clearance, remove the intake duct from throttle valve unit and lay it aside.

-- Install the engine support bridge 10-222 A.

Fig 19: Identifying Installed Engine Support Bridge 10-222
GWWN37-10319Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Attach it to the engine/transmission. Do not lift yet.

Fig 20: Identifying Hanging Engine/Transmission
GWWN37-10312Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the transmission mount to transmission mount bracket bolts -1-.

Fig 21: Identifying Engine Support Bracket Bolts
GWWN37-10309Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the transmission mount bracket -2- to transmission bolts.

-- Then, lower the engine/transmission using engine support bridge 10-222 A spindles about 6 turns.

-- Remove the transmission mount bracket.

-- Align the transmission support -3282- with the adjusting plate -3282/56-.

-- Guide the engine- / gearbox jack -V.A.G 1383 A- under the transmission and support the transmission. Do not lift it.

The transmission is disconnected from the engine in this position.

-- Remove the last engine/transmission bolt.

-- Carefully drain the transmission, ensure there is clearance to other components.

-- You should have permanently attached the transmission's diagnostic protocol for analysis to the transmission ready for shipment.

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