Transmission, Removing

Short Description:

The transmission is remove downward by itself.

From above:

The battery, air filter housing and starter are removed. The coolant hoses are clamped off. Before removing the subframe, the engine and transmission must be supported.

From underneath:

The pendulum support and the left drive axle are removed. The subframe remains in the vehicle.

Special tools and workshop equipment required

Engine Support Bridge 10-222 A
Adjustment Plate -3282/42A-
Adapter 10-222 A/18
Engine Support Adapter 10-222 A/3
Transmission Support -3282-
Insert Tool 18 mm -T10179-
Bracket -T10346-
Multipoint Socket -T10035-
Engine Support Feet 10-222 A/8
Hose Clamps up to 40 mm -3093-, if not available, use Hose Clamps up to 25 mm Dia. -3094-
Engine-/Gearbox Jack -V.A.G 1383 A-
Tensioning Strap -T10038-
Socket and Extended Bit -T10107 A- or Hex Extension -V.A.G 1669
Bracket with Spindle and Hook 10-222 A/10
Bracket -T10346-
Engine Support Device -3300 A-

Removing

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

-- Remove the left front wheel.

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

NOTE:

Do not lower the vehicle onto the floor after loosening the drive axle bolt.

-- Apply the brake pedal in order to remove the left drive axle bolt -arrow-. (2nd technician required).

Fig 1: Identifying Left Front Drive Axle Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the air filter housing. Refer to Removal and Installation .

-- Remove the battery, the battery tray bolts -arrows- and tray.

Fig 2: Identifying Battery Holder Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the connector -1- from the Mechatronic unit.

Fig 3: Identifying Starter And Bayonet Catch

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Remove the lower starter bolt first.

-- Disconnect the ground strap from the bracket.

-- Remove the selector lever cable from the transmission.

Fig 4: Identifying Lock Washers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use pliers to remove the lock washer. Do not use a sharpened lever otherwise the rubber grommet on the cable may get damaged.

Always replace both lock washers -arrows-.

-- Remove the cable from the transmission cable bracket. Do not bend the cable.

The cable can be removed later when the transmission is lowered. Pay attention to the cable while the transmission is being lowered.

Later, install the small lock washer only after having checked and adjusted the cable. Refer to SELECTOR LEVER CABLE, CHECKING .

-- Clamp off the coolant hoses to the cooler using either the hose clamps up to 40 mm -3093- or the hose clamps up to 25 mm dia. -3094- and remove the hoses.

Fig 5: Identifying Coolant Hoses Clamped Using Clamps 3094

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the upper engine/transmission bolts.

Fig 6: Identifying Special Tool T10179

Courtesy of VOLKSWAGEN UNITED STATES, INC.

These tools are suitable for this.

Fig 7: Identifying Special Sockets

Courtesy of VOLKSWAGEN UNITED STATES, INC.

It is advisable to complete the work under the vehicle now. This prevents the weight of the engine from resting on the engine support bridge and therefore on the body for a long period of time.

-- Remove the noise insulation and lower section of the left front wheel housing liner if necessary. For the noise insulation, refer to Description and Operation , for the wheel housing liner, refer to Removal and Installation .

-- Remove the charge air hose between the charge air cooler and the charge air pipe. Refer to Description and Operation .

Fig 8: Identifying Hose And Clamps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the fan shroud -arrow-. Refer to Removal and Installation .

Fig 9: Identifying Fan Shroud

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the wire bracket from the large transmission cover (quantity: 2 M6 nuts).

Fig 10: Identifying Nuts And Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tightening specification: 10 Nm

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

Fig 11: Identifying Connector And Oil Level Thermal Sensor G266

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the exhaust system suspended mount bolts -arrows- from the subframe.

Fig 12: Identifying Bracket For Exhaust System From Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the exhaust system at the double clamp -arrows-.

Fig 13: Identifying Exhaust System Double Clamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Either tie up the front exhaust pipe or lay it on the tunnel bridge.

-- Remove the left drive axle. Refer to Removal and Installation .

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

Fig 14: Identifying Drive Axle Heat Shield Bolts And Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the right drive axle from the transmission. Refer to Removal and Installation .

-- Secure the drive axle to the strut using a tensioning strap -T10038-.

Fig 15: Identifying Ratchet Strap On Right Drive Axle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Do not damage the surface of the dive axle.

-- Remove the pendulum support. Remove the bolt -1- first, then remove the bolts -2 and 3-.

Fig 16: Identifying Pendulum Support & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the right transmission flange shaft using the socket and extended bit -T10107 A-.

Fig 17: Identifying Removal Of Right Transmission Flange Shaft Using The Socket And Extended Bit -T10107 A-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The bolt has a 6 mm inner hex socket. It can also be removed and installed using the hex extension -V.A.G 1669-.

-- To remove and install the flange shaft, install 2 bolts into the flange and counter hold it using a pry bar.

Fig 18: Identifying Right Flange Shaft Countersunk Bolt, Socket And Key T10107

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the flange shaft and the pressure spring.

-- Close the opening for the flange shaft with a suitable plug.

-- When installing, press the flange shaft against the transmission with a pry bar and install the bolt.

Tightening specification: 30 Nm

-- Remove the filler pieces from both fender upper edges.

-- Disconnect any hoses and wires in the area of the lifting eyes on the engine.

Fig 19: Identifying Engine Support Bridge 10-222 A And Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the engine support bridge 10-222 A on the upper longitudinal member.

CAUTION:

Installing the engine support bridge on the fenders will damage them.

-- Support the engine and the transmission using the engine support bridge 10-222 A and bracket with spindle and hook 10-222 A/10. Do not lift up yet.

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

Fig 20: Identifying Transmission Support Plate And Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Lower the engine/transmission using the spindle until it is possible to remove the bracket -A-.

Three turns maximum on each spindle are enough to remove the bracket -arrow-.

In many cases it is not necessary to lower the spindles when removing the transmission later.

Remove the bracket -arrow-.

Fig 21: Identifying Transmission Support Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- If necessary, remove the bracket with the secondary pump and lay the pump aside.

-- Remove the remaining bolts except for one bolt between the engine and the transmission.

It is advisable to leave a bolt that is easily accessible.

-- Remove the right bolt for the heat shield -1- from the subframe.

Fig 22: Identifying Bracket -T10346-, Bolt -2- And Special Tool -3300A-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the bracket -T10346- to the subframe with a bolt -2-.

Bolt -2- = M6 x 20

-- Attach the engine support device -3300 A- to the bracket -T10346-.

-- If possible, place the support device against the engine crankcase.

-- Push the engine/transmission far enough forward until there is enough clearance to remove the transmission.

NOTE:

Be careful not to bend or damage the connecting lines, hoses and radiator when moving the engine/transmission subassembly.

-- Align the transmission support -3282- with the adjustment plate -3282/42A-.

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

The transmission is disconnected from the engine in this position.

-- Remove the last engine/transmission bolts.

-- Separate the transmission from the engine while being careful of selector lever cable and lower the transmission.

Transport the transmission and secure it to the assembly stand. Refer to TRANSMISSION, TRANSPORTING AND SECURING TO THE ASSEMBLY STAND .

Install the transmission. Refer to TRANSMISSION, INSTALLING .