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Transmission, Removing

Short Description 

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

Remove the air filter housing from the top. Both the engine and the transmission are supported and it is possible to remove the transmission mount.

"From underneath" : 

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

NOTE:

The subframe is not removed.

Special tools and workshop equipment required 

Removing 

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

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

NOTE:

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

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

Fig 1: Identifying Left Front Drive Axle Bolt
GWWN37-10425Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Remove the air filter housing bracket bolts -arrows- and then remove the bracket.

Fig 2: Locating Air Filter Bracket Mounting Bolts
GWWN27-10434Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pry the cable -1- off the selector shaft lever -3- using a wrench -2-.

Fig 3: Identifying Selector Lever Cable, Lever/Selector Shaft And 10mm Open-End Wrench
GWWA37-0577Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
CAUTION:

The retainers on the selector lever cable break very easily. The complete selector mechanism with cable must be replaced if one of the tabs breaks off.

-- Squeeze the retainers together on the selector lever cable -arrows- and remove the selector lever cable from the cable bracket.

-- Do not bend the cable.

-- Remove the selector lever cable -1- from the bracket -arrow- on the transmission.

Fig 4: Identifying Clip Securing Selector Lever Cable
GWWA37-0581Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the coolant lines -1 and 2- from the engine.

Fig 5: Identifying Coolant Lines At Engine
GWWN37-10314Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal off the coolant hoses using either hose clamps up to 40 mm 3093 or hose clamp up to 25 mm dia.3094 and then remove the lines.

Fig 6: Locating Hose Clamps Position On ATF Cooler Hoses
GWWN37-10120Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the upper engine/transmission bolts.

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

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

-- Disconnect the connector from the transmission.

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

Fig 7: Identifying Support Bracket, Pendulum And Bolts
GWWN10-10677Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 8: Locating Drive Axle Heat Shield Bolts
GWWN34-11369Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unbolt the right drive axle from the transmission and then move it as far as possible forward and secure it to the strut in this position.

Fig 9: Identifying Ratchet Strap
GWWN37-10373Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the six torque converter nuts -arrows- using the socket SW15V/175. Counter hold the torque converter with a screwdriver.

Fig 10: Identifying Torque Converter Nuts
GWWN37-10304Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Clamp off the Automatic Transmission Fluid (ATF) hoses/pipes -2- using the hose clamps up to 25 mm dia.3094.

Fig 11: Identifying ATF Lines
GWWN37-10308Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

Fig 12: Identifying Installed Engine Support Bridge 10-222 A
GWWN34-11115Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 13: Identifying Engine Support Bracket Bolts
GWWN37-10309Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Remove the transmission mount bracket -2-.

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

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

-- Remove the lower engine/transmission bolts.

-- Separate the transmission from the engine.

NOTE:

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

-- Some of the components from the old transmission must be removed and installed on the new transmission.

Fig 14: Identifying Mounting Bracket And Bracket For Selector Lever Cable
GWWN37-10294Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the transmission. Refer to TRANSMISSION, INSTALLING .



Short Description 

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

Remove the air filter housing from the top. Both the engine and the transmission are supported and it is possible to remove the transmission mount.

"From underneath" : 

The pendulum support and both drive axles are removed. The subframe remains in the vehicle.

After removing the bevel box, support the transmission, remove the last bolt connecting 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 are at the same height.

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

NOTE:

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

-- Loosen both drive axles.

-- While a second technician presses the brake, remove the drive axle bolts -arrow- from the left and right drive axles.

Fig 1: Identifying Left Front Drive Axle Bolt
GWWN37-10425Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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 air filter housing and the bracket underneath it. Refer to [For transmission(s) 09M] Removal and Installation .

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

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

-- Pry the cable -1- off the selector shaft lever -3- using a wrench -2-.

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

The retainers on the selector lever cable break very easily. The complete selector mechanism with cable must be replaced if one of the tabs breaks off.

-- Squeeze the retainers together on the selector lever cable -arrows- and remove the selector lever cable from the cable bracket.

-- Do not bend the cable.

-- Remove the selector lever cable -1- from the bracket -arrow- on the transmission.

Fig 3: Identifying Clip Securing Selector Lever Cable
GWWA37-0581Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

-- Remove the upper engine/transmission bolts.

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

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

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

-- Remove the right and left drive axles. Refer to [For transmission(s) 02E, 02Q, 09M] Removal and Installation .

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

Fig 6: Identifying Support Bracket, Pendulum And Bolts
GWWN10-10677Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 7: Identifying Right Driveshaft Heat Shield And Bevel Box
GWWA39-0277Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the driveshaft flexible disc to output flange bolts -arrows-.

Fig 8: Locating Driveshaft Flexible Disc Bolts
GWWA10-10247Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 9: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft
GWWN37-10410Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

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

The seal in the driveshaft must not be damaged.

Fig 10: Identifying Driveshaft Flange Shaft Seal
GWWV39-1817Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transmission bracket bolts/studs -1 and 2- and bracket -A- from between the cylinder block and the bevel box.

Fig 11: Identifying Tightening Sequence
GWWN37-10320Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 12: Identifying Bevel Box To Transmission Top Bolts
GWWN34-11003Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 13: Identifying Lower Bevel Box Mounting Bolts At Manual Transmission
GWWN34-10500Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 14: Identifying Wooden Block
GWWN39-10324Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the engine and transmission slightly forward and secure with a suitable block of wood -A-.

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

-- Remove the plug -arrow-.

Fig 15: Locating Plugs
GWWN37-10322Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove all the bolts between the engine and the transmission with the exception for one easily accessible bolt.

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

-- Clamp off the Automatic Transmission Fluid (ATF) pipes/hoses -2- using the hose clamps up to 25 mm dia.3094.

Fig 16: Identifying ATF Lines
GWWN37-10308Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -1- and the ATF pipes/hoses -2- from the transmission.

-- Seal off the ATF pipes/hoses and transmission with clean plugs.

-- To ensure the rear engine support bridge spindle has sufficient clearance, remove the connecting pipe from the throttle valve and lay aside.

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

Fig 17: Identifying Installed Engine Support Bridge 10-222 A
GWWN34-11115Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 18: Identifying Engine Support Bracket Bolts
GWWN37-10309Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Remove the transmission mount bracket -2-.

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

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

The transmission is separated from the engine in this position. 

-- Remove the last engine/transmission bolt now.

-- Carefully lower the transmission, ensure clearance to other components.

-- Install the transmission. Refer to TRANSMISSION, INSTALLING .