Transmission, Removing And Installing, Vehicles With V6 TDI Engine: Removing

-- If the vehicle has air suspension, activate the vehicle lift mode. Refer to Vehicle Lift Mode .

-- Carefully remove the engine cover from the 4 retaining pins one after the other -arrows-.

Fig 1: Identifying Removal Of Engine Cover From 4 Ball Studs -Arrow-

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-- Disconnect the battery ground cable with the ignition switched off. Refer to Battery, Disconnecting and Connecting .

-- Remove bracket -1- from the bulkhead -arrow-, so that the engine does not bump into the bracket when tilted.

Fig 2: Loosen The Nut -Arrow- And Remove The Bracket -1- From The Bulkhead

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-- Remove the noise insulation under the engine and transmission. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the noise insulation bracket -arrows-.

Fig 3: Identifying Bracket For Noise Insulation

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-- Remove the rear section of the exhaust system. Refer to OVERVIEW - MUFFLER [CGFA] , OVERVIEW - MUFFLER [CGRA] or OVERVIEW - MUFFLER [CNRB] .

-- Remove the front and rear driveshafts. Refer to OVERVIEW - DRIVESHAFT .

-- Remove the diesel particulate filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING .

-- Disconnect the connectors -1 through 3- from the transmission.

Fig 4: Connect Connectors -1 Through 3-

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-- Secure the : T40091/1 using the : T40091/4 , : T40091/5 and : T40093/6 to the body. For this purpose, screw in screws -A- (M8 x 30) next to the large opening -arrow- in the body.

Fig 5: Crossmember T40091/1 With The Adapters

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-- Insert the : T40091/6 with the : T40091/7 into the : T40093/6 .

-- Then mount the : T40091/6 and the : T40091/8 on the automatic transmission housing.

-- Remove the transfer case -B- with the transmission support -C-. Refer to Transfer Case, Removing and Installing .

-- Fasten the engine support bridge to the body. Refer to ENGINE, SUPPORTING IN INSTALLED POSITION [CGRA] .

NOTE:

The special tools needed for removing the transfer case must now be removed.

-- Support the engine with the engine support bridge from above, lower the transmission via the : T40091/6 and remove the : T40091/1 with the Adapters underneath the transmission.

-- Remove the heat shield -A- from the steering gear.

Fig 6: Identifying Steering Gear Heat Shield -A-

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NOTE:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.

To maintain the position of the steering wheel and steering gear, secure the steering wheel with adhesive tape.

-- Remove universal joint screw -B- and then remove the universal joint from the steering gear.

-- Remove the catalytic converter. Refer to OVERVIEW - EMISSIONS CONTROL [CGFA] , OVERVIEW - PRE-CATALYTIC CONVERTERS [CGRA] or OVERVIEW - EMISSIONS CONTROL [CNRB] .

-- Disconnect the selector lever cable from the ball head -1- using the : 80-200 and remove the lock washer -3-.

Fig 7: Identifying Selector Lever Cable, Removal/Installation

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A removed lock washer must not be used again. Always replace the lock washer.

NOTE:

Do not bend or kink the selector lever cable.

-- Remove catalytic converter bracket -1- from the transmission -arrows-.

Fig 8: Catalytic Converter Bracket Bolts -Arrows- And Bracket -1

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-- Remove heat shield -1- (for the coolant lines) and -2- (for the selector lever cable) from the transmission. Remove the screws -arrows A- and -arrows B-.

Fig 9: Heat Shield & Bolts

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-- Remove the vacuum hose -1- from the vacuum pipe -2- (leading to the brake booster).

Fig 10: Identifying Vacuum Hose & Pipe

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-- Place the : VAS6208 under the engine/transmission.

-- Clamp off the coolant hoses on the left side of the transmission with : 3094 .

Fig 11: Coolant Hoses & Hose Clamps Up To 25 Mm Dia. 3094.

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-- Then remove the hose clamps from coolant pipes -A- using, for example, : VAG1921 . Remove the coolant hoses from the coolant pipes.

-- Clamp off the coolant hoses on the right side of the transmission with : 3093 and disconnect the coolant hoses from coolant pipes -A-.

Fig 12: Coolant Pipes -A- & Hose Clamps Up To 40 Mm Dia. 3093

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-- Remove the bleed hose -B- from the clip on the coolant pipe.

Fig 13: Coolant Pipes, Breather Hose & Clips

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-- Remove the coolant pipes -A- from the transmission -arrows-.

-- Remove the bolts -1 and 2- and then remove the ATF lines from the transmission. Collect the escaping oil.

Fig 14: Identifying Transmission Fluid Pipe Bolts -1 & 2

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-- Seal the ATF lines with suitable plugs from the : VAS6122 (to prevent dirt from getting into the lines).

-- Remove the ATF preheater from the transmission -arrows-.

Fig 15: Identifying Pre-Heater Bolts

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-- Disconnect the connector -1- from the Cooling Oil Valve -N471- -2- and remove the ATF preheater with the coolant pipes from the transmission.

Fig 16: Cooling Oil Valve -N471-

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-- If equipped, disconnect the connector -1- from the Transmission Fluid Auxiliary Hydraulic Pump 2 -V476- -2-.

Fig 17: Disconnect The Connector -1- From The Transmission Fluid Auxiliary Hydraulic Pump -V475- -2-.

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-- Disconnect the connector -1- from the Multifunction Transmission Range Switch -F125- -2-.

Fig 18: Connect The Connector -1- To The Multifunction Transmission Range Switch -2-.

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-- Remove the starter. Refer to STARTER, VEHICLES WITH AUTOMATIC TRANSMISSION .

-- Insert the guide pin for the : T40058 as follows:

Fig 19: Guide Pin & Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- To loosen the bolts for the torque converter, counterhold the crankshaft at the drive plate using the : T40058 and the offset open-end wrench.

Fig 20: Counter Hold Crankshaft Using Socket T40058

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NOTE:

Turn the crankshaft only in the direction of engine rotation -arrow-.

Instead of the : T40058 , the engine can also be rotated with the following tools:

: T40257
: T40263
: T40314

-- Connect the tools as shown.

Fig 21: Crankshaft Turning Tool, Wrench - 21 MM & Adapter

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Socket 21 mm for ¹ /₂ -Drive

Fig 22: Identifying Wrench - 21 MM T40263

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-- Remove cap -1-.

Fig 23: 6 Torque Converter Bolts -Arrows- & Cap

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-- Remove six torque converter bolts -arrows- in the opening of the removed starter (turn the crankshaft a ¹ /₃ rotation in the direction of engine rotation).

NOTE:

Loosen and tighten the torque converter bolts -arrows- on the drive plate -2- with a Torx 55 socket (100 mm long). Do not allow the bolts to fall into the transmission housing.

Replace the bolts after removing them.

-- Remove the top engine/transmission bolts -4 through 6- and the bottom bolts -8 through 10-. Bolts -3 and 7- remain screwed in.

Fig 24: Bolt Removal Sequence

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-- Place the : VAS6931 with the Universal Support on the bottom of the transmission. Place a wooden block between the transmission fluid pan and the Universal Support.

Fig 25: Engine-/Gearbox Jack V.A.G 1383 A With The Universal Support V.A.G 1359/2

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Secure the transmission with the : T10038 to the Universal Support.

-- Slightly relieve the pressure at the top of the engine and transmission using the engine support. Use the : VAS5085 to do this.

-- Remove the remaining engine/transmission bolts -3 and 7-.

-- Dismount the transmission from the engine, and press the torque converter off of the drive plate.

NOTE:

Make sure the torque converter cannot slip out of the transmission during the removal procedure.

-- Lower the transmission using the : VAS6931 . The Transmission Fluid Auxiliary Hydraulic Pump 2 -V476- -1- (if equipped) must not touch the subframe -2- -arrow- during this.

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-- After removing the transmission, use a : 30-211 A to secure the torque converter from falling out.

Fig 26: Identifying Bracket -30-211A- Attached To Secure Torque Converter

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