Diesel Vehicles, Transmission, Removing
Short Description
The transmission is remove downward by itself.
"From above" :
The battery, air filter housing and starter are removed. The steering gear wiring harness is disconnected and freed up. This way it can be lowered together with the subframe and the steering gear. The engine and transmission are supported before the transmission mount bracket is removed.
"From underneath" :
The subframe, with the pendulum support, the steering gear and both lower control arms are all removed together.
Both drive axles are separated from the transmission and remain inside the wheel bearing housings. Occasionally they will be moved to the side, but they still remain on the vehicle.
Special tools and workshop equipment required
- Transmission Support 3282
- Adjustment Plate 3282/42A
- Pin 3282/29
- Torque Wrench (5-50 Nm) VAG1331
- Torque Wrench (40-200 Nm) VAG1332
- Engine-/Gearbox Jack VAG1383A
- Engine Support Bridge 10-222A
- Hose Clamps Up to 25 mm Dia. 3094
- Hose Clamps Up to 40 mm 3093
- Tensioning Strap T10038
- Engine Support Basic Set T40091
- Engine Support Supplement Set T40093
- Engine Bung Set VAS6122
-- Move the selector lever into the "P" position.
-- Remove the engine cover, refer to[For engine(s) CPRA, CPKA] Removal and Installation[For engine(s) CDVB] Removal and Installation[For engine(s) CKRA] Removal and Installation[For engine(s) CVCA] Removal and Installation .
-- Remove the air filter housing, refer to [For engine(s) CKRA] Removal and Installation or [For engine(s) CVCA] Removal and Installation
-- Press the release button and remove the crankcase ventilation hose -1-.
-- Disconnect the connector on the crankcase ventilation hose -1-.
-- Free up the vacuum hoses -arrows-.
-- Remove the bolt -2-, move the charge air hose to the rear and pull it off the turbocharger.
-- Remove the battery and the battery tray, refer to [For engine(s) CVCA, CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Removal and Installation .
-- Remove the selector lever cable from the transmission -arrows-.
Use pliers to remove the lock washers. Do not use a sharp edged tool. Otherwise the selector lever cable could get damaged.
Remove the cable bracket -2- from the transmission, if necessary. To do so, remove the bolts -1- and the lock washer -3-.
Replace the bolts -1- and the lock washer.
Bolt -1- tightening specification, see -item 7- in SELECTOR MECHANISM OVERVIEW .
Remove the selector lever cable from the transmission cable bracket. Do not bend the cable.
You can also slide the cable back slightly from the cable bracket and remove it later when lowering the transmission. Watch the cable when lowering the transmission.
Later, during installation, only install "new" lock washers after you have checked and adjusted the cable, refer to SELECTOR LEVER CABLE, ADJUSTING .
-- Place lint free cloths on the transmission oil cooler and transmission to absorb leaking coolant.
When the engine is warm, the cooling system is under pressure.
Cover the cap on the expansion tank with a cloth and open it carefully before removing the coolant hoses.
-- Clamp off the coolant hoses using the Hose Clamps Up To 25 mm dia. 3093 or Hose Clamps Up To 40 mm 3094 and remove the hoses from the transmission oil cooler.
-- Seal the transmission oil cooler connections with plugs from the Engine Bung Set VAS6122.
-- Remove the starter -A-, refer to [For engine(s) CVCA, CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Removal and Installation .
Remove the "lower" starter bolt first.
Risk of destroying the Mechatronic unit with static electricity.
- Do not touch the contacts in the Mechatronic unit connector with hands.
-- To discharge any static electricity, touch a ground with hand (without wearing a glove), refer to ELECTRICAL COMPONENT LOCATION OVERVIEW .
-- Release and remove the connector -1- for the Mechatronic unit by turning it in the direction of the starter.
-- Remove all upper engine/transmission bolts.
These tools are suitable for this.
Special tools and workshop equipment required
- Multi-Point Socket T10035
- Socket, Multi-Point Bit XZN 14 T10061
- Bits T10099
- Insert tool 18 mm T10179
One bolt is located inside the hole for the starter -arrow-. Use the Socket, Multi-Point Bit XZN 14 T10061 to remove this bolt.
-- Disconnect any hoses and cables in the area of the lifting eyes on the engine.
-- Remove the plenum chamber cover, refer to Removal and Installation .
-- Remove the bolts -arrows- from the left and right lock carrier brackets.
-- Remove the lower mounts from the Adapters 10-222A/28 and replace them with the Adapters 10-222A/28-2.
-- Mount the Adapters 10-222A/28 with the Adapters 10-222A/28-2 on the left and right lock carrier brackets and secure them in the threaded holes for the lock carrier brackets.
- Use the bolts -arrows- from the Adapters 10-222A/28-2 for attaching the Adapter 10-222A/28 and not the lock carrier bracket bolts, refer to Fig 11.
- Bolt tightening specification: 8 Nm.
A second technician will be needed to install the Engine Support Bridge 10-222A to the vehicle in order to prevent the engine support bridge from tipping over.
Install the engine support bridge as follows:
- Adapter 10-222A/31-2
- Moveable joint
- Adapter 10-222A/31-1
- Moveable joint T40093/4
- Square pipe T40091/1
- Adapter 10-222A/28 with Adapter 10-222A/28-2
- Bracket With Spindle And Hook 10-222A /10
-- Slide the Moveable Joint T40091/3 (-2-) onto the square pipe from the Engine Support Bridge 10-222A.
- The bolts for the Moveable Joint T40091/3 (-2-) on the square pipe face the front.
-- Mount the Engine Support Bridge 10-222A onto the strut towers and have a second technician hold it to keep it from falling over.
-- Push the left and right Square Pipes T40091/1 (-5-) from the front, through the Adapters 10-222A/28 (-6-) and install the Moveable Joints T40093/4 (-4-) on each pipe.
-- Mount the Bracket With Spindle And Hook 10-222A/10 (-7-) on the left side Square Pipe T40091/1.
-- Slide the Rail With Holes T40091/2 (-8-) with the Mount T40093/5 (-9-) in the Moveable Joint T40093/4 (-4-).
- Adapter 10-222A/31-2
- Moveable joint T40091/3
- Adapter 10-222A/31-1
- Moveable joint T40093/4
- Square Pipe T40091/1
- Adapter 10-222A/28 with adapter 10-222A/28-2
- Bracket with Spindle and Hook 10-222A/10
- Rail with holes T40091/2
- Mount T40093/5
- Spindle 10-222A/11
-- Install the locking pins into the Rail With Holes T40091/2 (-8-) and secure them.
-- Tighten the threaded connections on the engine support bridge hand tight. Adjust the height of the engine support bridge parallel over the Adapters 10-222A/28.
-- Tension the engine/transmission subassembly using the Bracket With Spindle And Hook 10-222A/10 (-7-) and the Spindle 10-222A/11 (-10-) slightly, but do not lift it.
Vehicles with 2.0L 110 kW diesel engine
Mount the engine support bridge on the engine/transmission sub-assembly as follows:
- Engine Support Bridge - Engine Support 31 - Adapter 210-222A/31-2
- Engine Support - Basic Set - Moveable Joint T40091/3
- Engine Support Bridge - Engine Support 31 - Adapter 110-222A/31-1
- Engine Support - Basic Set - Square Pipe T40091/1
- Spindle from Engine Support Bridge 10-222A
- Engine Support Bridge - Engine Support 32 - Adapter 10-222A/32 with Engine Support Bridge - Engine Support 32 - Shackle 10-222A/32-1
- Engine Support Bridge - Engine Support 2810-222A/28 with Engine Support Bridge - Engine Support 28-2 10-222A/28-2
-- First slide the Moveable Joints item -2- onto the Square Pipe from the Engine Support Bridge 10-222A.
- The bolts for the Movable Joints T40091/3 item -2- point towards the front of the vehicle.
-- Mount the Engine Support Bridge 10-222A as shown in the image and have a second technician hold it to prevent it from tipping.
-- Place the Spindle item - 5- on an Engine Support - Basic Set - Square Pipe T40091/1 item - 4-.
-- Place the Engine Support Bridge - Engine Support 32 - Adapter 10-222A/32 item - 6- on the other Engine Support - Basic Set - Square Pipe T40091/1 item - 4-.
-- Slide both Engine Support - Basic Set - Square Pipes T40091/1 item - 4- from the front through Engine Support Bridge - Engine Support 28 10-222A/28 -item 7-.
-- Tighten all threaded connections on the Engine Support Bridge. While doing so, adjust the height of the Engine Support Bridge parallel over the Engine Support Bridge - Engine Support 2810-222A/28.
-- Connect the Engine Support Bridge - Engine Support 32 - Adapter 10-222A/32 item - 5- and Spindle item - 6- to the engine.
-1- = Engine Support Bridge - Engine Support 32 - Shackle 10-222A/32-1 from the Engine Support Bridge - Engine Support 32 - Adapter 10-222A/32.
-- Lightly pretension the engine/transmission sub-assembly, but do not lift it.
Continuation for all
-- Loosen the left and right front wheel bolts.
-- Raise the vehicle and remove the front wheels.
-- Remove the noise insulation, refer to DESCRIPTION AND OPERATION .
-- Remove the left and right front wheel housing liner, refer to Removal and Installation .
-- Remove the electrical wires from the bracket, remove the nuts -arrows- (two M6 nuts) and bracket from the transmission front cover.
-- Route the wires near the transmission front cover upward and secure them.
-- Disconnect the exhaust system at the clamping sleeve and remove the exhaust system suspended mount bolts -arrows- from the subframe.
-- Tie up the front exhaust pipe.
Watch the wire on the front exhaust pipe and catalytic converter. The wires remain attached to the front exhaust pipe.
Do not bend the coupling element in the front exhaust pipe more than 10° or it will be damaged.
The coupling element can also be locked in its installed position using the Transportation Lock T10404 -arrow-.
-- Remove the right drive axle heat shield bolts -arrows- and shield, if equipped.
-- Remove the drive axles from the transmission, refer to [For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Removal and Installation .
-- Tie the right drive axle up as high as possible.
-- Move the left drive axle to the rear and secure it. Be careful not to damage the surface protection.
-- Remove the subframe with steering gear, refer to [For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Removal and Installation .
-- Remove the transmission mount to transmission mount bracket bolts -2- and remove the transmission mount bracket to transmission bolts -1-.
-- Lower the engine/transmission approximately 50 mm -a- using the spindles on the Engine Support Bridge 10-222A.
-- Remove the transmission mount bracket in direction of -arrow-.
To remove the transmission, the Adjustment Plate 3282/42A must be installed on the Transmission Support 3282 and they must both be installed on the Engine-/Gearbox Jack VAG1383A.
-- Align the arms of the transmission support so that they match up with the holes in the Adjustment Plate 3282/42A.
-- Install the support elements onto the Adjustment Plate 3282/42A as shown.
-- Place the Engine-/Gearbox Jack VAG1383A under the vehicle.
- The arrow symbol on the Adjustment Plate 3282/42A points in the direction of travel.
-- Align the Transmission Support 3282 so that it is parallel to the transmission.
-- Screw the Pins 3282/29 into the transmission.
-- Secure both support elements to the transmission as shown.
Deviating from the illustration of the adjustment plate, the front transmission support is illustrated mounted to the transmission with an M10 x 50 mm bolt -arrow-. Install a M12 bolt between the mount and the transmission housing.
An All Wheel Drive (AWD) Direct Shift Gearbox (DSG®) is shown in the illustration. The mounting elements on a Front Wheel Drive (FWD) are identical.
-- Lift the Engine-/Gearbox Jack VAG1383A to support the transmission from underneath.
The transmission is disconnected from the engine in this position.
-- Remove all remaining engine/transmission bolts.
-- Remove the transmission from the engine while being careful of the selector lever cable and lower the transmission.
Pay attention to the wires when lowering the transmission.
Transport the transmission and secure it to the assembly holder, refer to TRANSMISSION, TRANSPORTING .
Install the transmission, refer to TRANSMISSION, INSTALLING .