Removal And Installation: Transmission: Notes

Special tools and workshop equipment required

Engine support bridge 10 - 222 A
Adapter 10 - 222 A /8
Shackle 10 - 222 A /12
Hose Clamps Up To 25 mm Dia. 3094
Transmission support 3282
Adjustment plate 3282 /36
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmissions jack V.A.G 1383 A
Socket wrench insert V/175

Vehicles with 2.5L 5-cylinder engine

Special tools and workshop equipment required

Tension strap T10038
Socket key T03003

Removing

NOTE:

Replace all cable ties which are opened or cut open when removing the transmission in the same position during installation.

-- Move selector lever in position "N".

-- Remove engine cover.

-- First determine whether a coded radio is installed. In this case, determine anti-theft coding.

-- Switch ignition off and disconnect battery Ground (GND) cable.

-- Remove power steering reservoir from battery holder, do not kink hoses while doing this.

-- Connect reservoir to lock carrier.

-- Remove battery and battery holder Removal and Installation .

NOTE:

Observe safety precautions before disconnecting the battery.

-- Disconnect intake hose -1- and connector -2- from Mass Air Flow (MAF) sensor.

Fig 1: Removing Bolts And Air Filter Housing

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-- Disconnect Secondary Air Injection (AIR) pump hose -3- from air filter housing.

-- Remove bolts -4-, -5- and -6-.

-- Remove air filter completely.

-- Press off selector lever cable -1- from lever/selector shaft -6- using an open end wrench.

Fig 2: Identifying Selector Lever Cable -1- And Multi-Function Switch Connector -5-

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NOTE:

Do not loosen bolt -2- !

-- Remove both bolts -3-.

-- Release selector lever cable from transmission at clip -4- and tie up.

NOTE:

Do not bend selector lever cable.

-- Disconnect connector -5- from multi-function switch.

-- Disconnect electrical connections from starter.

-- Remove starter -A- Removal and Installation .

Fig 3: Identifying Starter, 14 Pin And 18 Pin Connectors

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-- Disconnect (14-pin) connector -B- and (8-pin) connector -C- from transmission.

NOTE:

If connectors -B- or -C-, which are installed to the transmission, were damaged or destroyed during removal or a vehicle accident, the corresponding wiring harness with 14-pin or 8-pin connectors must be replaced WIRING HARNESS WITH 14-PIN CONNECTOR or WIRING HARNESS WITH 8-PIN CONNECTOR .

-- Clamp off ATF cooler hoses using Hose Clamps Up To 25 mm Dia. 3094 and disconnect from ATF cooler.

Fig 4: Clamping Off ATF Cooler Hoses Using Hose Clamps Up To 25 Mm Dia. 3094

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-- Seal ATF cooler with clean plugs.

-- Remove Ground (GND) cable from connecting bolt at top of engine/transmission.

-- Remove upper connecting bolts for engine/transmission.

-- Insert Engine support bridge 10 - 222 A with adapters 10 - 222 A /8.

NOTE:

Do not place adapter 10 - 222 A /8 on to mounting bolts for fender/front section.

-- If hose and cable connections are found in the area of engine lifting eyes for engine support bridge 10 - 222 A, they must be removed now.

Fig 5: Inserting Engine Support Bridge 10 - 222 A With Adapters 10 - 222 A /8.

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-- If necessary, secure hook of left spindle (on transmission side) via a shackle 10 - 222 A /12 on engine lifting eyelet.

Vehicles with 2.5L 5-cylinder engine

-- Remove plenum chamber end plate Removal and Installation .

-- Disconnect wires -1- from transport strap -3-.

Fig 6: Identifying Location Of Wires, Transport Strap And Bolts

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-- Remove bolts -2- and remove transport strap -3-.

-- Insert a shackle 10 - 222 A /12 into engine eyelet -arrow-.

-- Attach engine support bridge 10 - 222 A with adapter 10 - 222 A /8 and adapter 10 - 222 A /3 in front of gas-filled strut for hood.

Fig 7: Attaching Engine Support Bridge To Engine

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-- Place tension belt T10038 behind pins -arrows- around exhaust system and hang them on right spindle.

Continuation for all vehicles

-- Take up weight of engine/transmission assembly on spindles.

-- Remove both front wheels.

-- Remove noise insulation -arrows-.

Fig 8: Identifying Noise Insulation Fasteners

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-- Remove left noise insulation.

-- Remove noise insulation holder -1-.

Fig 9: Identifying Power Steering Line And Pendulum Support

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-- Disconnect line -2- of power steering on transmission -arrows A-.

-- Remove left drive axle -3- completely Removal and Installation .

-- Remove pendulum support -4- -arrows B-

-- Mark installation position of ball joint bolts -arrows- on control arm.

Fig 10: Identifying Control Arm And Ball Joint To Control Arm Fasteners

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-- Remove bolts -arrows-.

-- Remove coupling rod -A- from control arm.

NOTE:

This work step is necessary so that the right drive axle must not be disconnected from the wheel bearing (wheel hub).

Right drive axle must only be disconnected from the transmission.

-- If installed, remove protective cap -A- for inner right constant velocity joint from engine -arrows-.

Fig 11: Removing Right Drive Axle From Transmission

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-- Remove right drive axle -B- from transmission in direction of -arrow- Removal and Installation .

NOTE:

There is no separate flange shaft in the transmission, but rather the drive axle is inserted into transmission.

When prying the drive axle out of transmission, only the special tool must be used which is described in the Removal and Installation . If removed using other means, e.g. screwdriver or assembly iron, transmission or the drive axle will be damaged and must be replaced.

-- Bring right drive axle -B- upward and secure (tie up).

Fig 12: Identifying Torque Converter Cover Cap

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-- Unclip cap for torque converter cover -A-.

-- Remove 6 torque converter nuts -arrow- using socket wrench insert V/ 175.

Fig 13: Identifying Access To Torque Converter Nuts (Qty. 6)

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Vehicles with 2.5L 5-cylinder engine

-- Turn crankshaft 60° using Socket key T03003 for each nut in turn.

Fig 14: Turn Crankshaft 60 Degrees Using Socket Key T03003

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Continuation for all vehicles

CAUTION:

If not all 6 nuts are removed from torque converter, torque converter will be pulled out of engine when removing the transmission!

-- Disconnect exhaust system behind front exhaust pipe at double clamp.

-- Tie up exhaust system.

CAUTION:

Do not bend the flexible element of the exhaust system more than 10°, otherwise it may be damaged.

-- Remove transmission bracket -A- (remove bolts -1- and -2-).

Fig 15: Removing And Installing Transmission Mount

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-- Carefully bring engine with transmission into tilt position. To do so, screw down left spindle (on transmission side) on engine support bridge 10 - 222 A approx. 50 mm.

Transmission support 3282 is attached to adjustment plate 3282/36 for removing 6 Spd. Automatic Transmission 09G.

-- Align transmission support arms to correspond with holes in template.

-- Install attachments as depicted on adjustment plate 3282/36.

-- Place transmission jack under vehicle, arrow symbol on adjustment plate 3282/36 points in direction of travel/vehicle.

Fig 16: Setting-Up Transmission Jack Under Vehicle

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-- Align adjustment plate 3282/36 parallel to transmission.

-- Secure transmission on transmission support 3282 using bolt -A-.

-- Support transmission from below by raising transmission support.

-- Remove lower connecting bolts for engine/transmission.

-- Remove rear connecting bolt for engine/transmission at bottom -arrow-.

Fig 17: Location Of Rear Connecting Bolt For Engine/Transmission At Bottom

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-- Press transmission off from engine, when doing this press torque converter -A- using a screwdriver -B- out of drive plate in direction of -arrow-.

Fig 18: Pressing Torque Converter Out Of Drive Plate (In Direction Shown)

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-- Press torque converter against ATF pump.

-- Carefully swivel transmission toward subframe.

-- Carefully lower transmission and guide it past at subframe.

-- When lowering, guide power steering pressure line past transmission.

-- Secure torque converter from falling out e.g. using a wire.

Installing

Installation is in reverse order of removal. Note the following:

-- Before installing transmission, make sure torque converter is correctly inserted in transmission TORQUE CONVERTER, INSTALLING .

CAUTION:

In case of an incorrectly installed torque converter, the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is connected to the engine.

-- Make sure alignment sleeves -A- for centering engine/transmission are installed in cylinder block. Install if necessary.

Fig 19: Identifying Transmission To Engine Alignment Sleeves And Connecting Bolts

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-- Make sure intermediate plate is correctly seated on engine.

-- Install all engine/transmission connecting bolts items 1 to 8, see tightening torques TRANSMISSION .

-- Install 6 new nuts -arrow- for mounting torque converter to drive plate using socket wrench insert V/ 175, see tightening torques TRANSMISSION .

Fig 20: Identifying Access To Torque Converter Nuts (Qty. 6)

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Vehicles with 2.5L 5-cylinder engine

-- Turn crankshaft 60° using Socket key T03003 for each nut in turn.

Fig 21: Turn Crankshaft 60 Degrees Using Socket Key T03003

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Continuation for all vehicles

NOTE:

Nuts must always be replaced.

-- Install subframe mount as follows:

-- Place transmission bracket -A- between transmission and transmission mount

Fig 22: Removing And Installing Transmission Mount

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-- Carefully pull up transmission to transmission mount using engine support bridge spindles.

CAUTION:

Before installing the transmission bracket/transmission mounting bolts, ensure that the bracket and mounting are absolutely parallel to one another or the threads will be damaged. Press the transmission upward in the area of the final drive using Engine/transmission jack V.A.G 1383 A, if necessary.

-- Tighten bolts -1 - and -2-, see tightening torques TRANSMISSION .

Fig 23: Removing And Installing Transmission Mount

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CAUTION:

Only remove engine support bridge 10 - 222 A when bolts for left and right subframe mounts are tightened to tightening torque.

Vehicles with 2.5L 5-cylinder engine

-- Install plenum chamber end plate Removal and Installation .

Continued for all vehicles

-- Install pendulum support -4-, see tightening torques TRANSMISSION .

Fig 24: Identifying Power Steering Line And Pendulum Support

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-- Connect power steering line -2- to transmission -arrows A- Removal and Installation .

-- Install drive axles, when doing this replace transmission-side circlips on to drive axles Removal and Installation .

-- Install battery holder and battery Removal and Installation .

-- Observe safety precautions after connecting battery Removal and Installation

-- Check selector lever cable adjustment and adjust if necessary SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Check ATF level and top off ATF LEVEL .

-- Code radio Diagnosis and Testing .