Transmission, Removing, AWD
Special tools and workshop equipment required
- Hose Clamps - Up To 25 mm: 3094
- Engine Bung Set: VAS6122
- Torque Wrench 1331 5-50Nm: VAG1331
- Torque Wrench 1332 40-200Nm: VAG1332
- Grease for Clutch Disc Shaft Splines. Refer to the Parts Information
- Allocate the grease for gearshift mechanism. Refer to the Parts Information.
-- Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .
-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
-- Remove the battery and the battery tray. Refer to BATTERY, REMOVING AND INSTALLING .
-- Remove the shift cable lock washer -1- from the transmission selector lever -2-. Remove the cable from the pin -arrow-.
-- Remove the cable retainer from the selector cable.
- To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
-- Pull the safety mechanism all the way forward in direction of -arrow 1-. Then lock it to the left in direction of -arrow 2-.
-- Then push the selector relay lever forward in direction of (-arrow 3-).
Remove cable retainer only if selector relay lever is removed. Refer to Figure.
-- Remove nut -1- and bolts -2- and set the cable bracket and cables off to the side.
-- Remove the washer fluid reservoir. Refer to WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .
Brake fluid must not come into contact with the longitudinal member or transmission. If it does, clean the area thoroughly.
-- Clamp off the clutch master cylinder supply hose using : 3094 .
A slight deformation stays on the supply hose after the : 3094 has been removed.
The supply hose is therefore not defective.
After removing the : 3094 , the supply hose must be formed back into its original shape.
-- Place a lint-free cloth under the bleeder.
-- Remove the clip -arrow- all the way and then remove the hose/line assembly -A- from the bleeder.
-- Tie up wire.
The ground cable -B-, if present, is installed later in the procedure.
-- Seal the open lines and connections with clean plugs from the : VAS6122 .
There is a risk of contamination from the leaking brake fluid.
- Do not use the clutch pedal if the hose/line assembly from the clutch slave cylinder bleeder is disconnected.
-- Remove the upper engine/transmission connecting bolts -arrows-.
-- Remove windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .
-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
-- Install the : 10-222A as follows. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION .
Disconnect any hose- and cable connections near the engine lifting eyes for the : 10-222A .
-- Disconnect the front left connectors from the transmission:
- Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
- Back-Up Lamp Switch -F4-
-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .
-- Remove the lower section of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .
-- Remove the starter. Refer to STARTER, REMOVING AND INSTALLING .
-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.
-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .
-- Remove the drive axle heat shield, if equipped, from the bevel box (-arrows-). Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .
-- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection. Refer to DRIVE AXLE, REMOVING AND INSTALLING .
Risk of damaging the decoupling element
- Pay attention. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM .
-- Remove bolts -1 and 2- and transmission support.
-- Remove the bolts -arrows- and remove the heat shield -1-.
-- Mark the position of the driveshaft with the flexible disk with respect to the bevel gear flange with paint.
-- Remove the driveshaft from the bevel box -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .
-- Push the front driveshaft all the way back and tie it up.
-- If present, remove nut -arrow- and ground cable.
-- Remove the bolts -arrows- from the transmission mount.
-- Turn the spindles on the : 10-222A and lower the transmission to dimension -a-.
- Dimension -a- = 60 mm
-- Remove bolts -arrows- and transmission support from transmission.
-- Remove the bolts -2- from the transmission/engine connection.
The transmission to engine connection bolts -1 and 3- will be removed later in the procedure.
Align the : 3282 with the : 3282/33 in order to install the transmission.
-- Align the arms of the Transmission Support so that they match up with the holes in the Adjustment Plate.
-- Install the Support Elements -A- as illustrated on the Adjustment Plate.
-- Install the Mounting Element -C- instead of the : 3282/29 .
-- Align the Adjustment Plate so that it is parallel to the transmission.
-- Install the : 3282/29 into the rear hole for the pendulum support bolt on the transmission.
-- Secure the : VW771/40 inside the threaded hole in the transmission housing as illustrated.
-- Secure the transmission on the : 3282 with an M10 x 20 bolt -A-.
The needle bearing drift -B- must be flush with the guide on the : 3282 -arrow-.
-- Position the : VAS6931 under the vehicle. The arrow on the adjusting plate points in direction of travel.
-- Remove the engine/transmission connecting bolt -C-.
-- Remove the engine/transmission connecting bolt -arrow- next to the bevel gear -A-.
-- Separate the transmission from the engine (alignment sleeves).
-- Guide the bevel box and flange -C- past the driveshaft -A- and exhaust system -B-.
Pay attention to the lines when lowering the transmission.