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.
The subframe is not removed.
Special tools and workshop equipment required
- Engine Support Bridge 10-222 A
- Bracket for Engine 10-222 A/1
- Adapter 10-222 A/18
- Adjusting Plate 3282/56
- Bracket T10013
- Insert Tool 18 mm T10179
- Transmission Support 3282
- Hose Clamps Up to 25 mm Dia.3094, (Qty: 4)
- Tensioning Strap T10038
- Wedge Tool T10161
- Engine-/Gearbox Jack V.A.G 1383 A
- Engine Bung Set VAS 6122
- Socket SW15V/175
- Drip Tray for VAS 6100VAS 6208
Removing
-- Lift the vehicle, all 4 lift points of the hoist are at the same height.
-- Move the selector lever into the "P" position.
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).
-- 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.
-- Pry the cable -1- off the selector shaft lever -3- using a wrench -2-.
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.
-- Disconnect all electrical connections to the transmission and starter that are "easily accessible from above".
- Multifunction transmission range switch
- Starter
- Ground cable to the transmission mount bracket
-- Remove the coolant lines -1 and 2- from the engine.
-- 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.
-- 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-.
-- Remove the left drive axle. Refer to Removal and Installation .
-- Remove the right drive axle heat shield bolts -arrows- and shield, if equipped.
-- 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.
-- Remove the six torque converter nuts -arrows- using the socket SW15V/175. Counter hold the torque converter with a screwdriver.
-- Clamp off the Automatic Transmission Fluid (ATF) hoses/pipes -2- using the hose clamps up to 25 mm dia.3094.
-- 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.
-- Attach it to the engine/transmission. Do not lift yet.
-- Remove the transmission mount to transmission mount bracket bolts -1-.
-- 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.
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.
- Starter with wiring harness bracket
- Transmission mount bracket
- Selector lever cable brackets
-- 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.
The subframe is not removed.
Special tools and workshop equipment required
- Engine Support Bridge 10-222 A
- Bracket for Engine 10 - 222 A/1
- Adapter 10-222 A/18
- Adjusting Plate 3282/56
- Bracket T10013
- Insert Tool 18 mm T10179
- Transmission Support 3282
- Hose Clamps Up to 25 mm Dia.3094, (Qty: 4)
- Tensioning Strap T10038
- Wedge Tool T10161
- Engine-/Gearbox Jack V.A.G 1383 A
- Engine Bung Set VAS 6122
- Counterhold Tool T10172
Removing
-- Lift the vehicle, all 4 lift points of the hoist are at the same height.
-- Move the selector lever into the "P" position.
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.
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".
- Multifunction transmission range switch
- Starter
- Ground cable to the transmission mount racket
-- Pry the cable -1- off the selector shaft lever -3- using a wrench -2-.
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.
-- 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.
-- Remove the coolant lines -1 and 2- from the engine and disengage the wiring harness.
-- 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-.
-- Remove the right drive axle heat shield bolts -arrows- shield.
-- Mark the position of the driveshaft flexible disc to the bevel box output flange.
-- Remove the driveshaft flexible disc to output flange bolts -arrows-.
-- Counter hold the rear final drive to loosen and tighten the driveshaft flexible disc bolts.
To loosen the next bolt, rotate the driveshaft by turning the rear wheels.
The seal in the driveshaft must not be damaged.
-- Remove the transmission bracket bolts/studs -1 and 2- and bracket -A- from between the cylinder block and the bevel box.
-- Remove the bevel box upper bolts -arrows- from the transmission.
-- Remove the bevel box lower bolts -arrows- from the transmission.
-- Disconnect the connector -1- from the oil level thermal sensor.
-- 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-.
-- 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.
-- 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.
-- Attach it to the engine/transmission. Do not lift yet.
-- Remove the transmission mount to transmission mount bracket bolts -1-.
-- 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 .