Transmission, Removing

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS6931
Hose Clamps - Up To 25 mm: 3094
Tensioning Strap: T10038
Engine Bung Set: VAS6122
Pry Lever: 80-200
Insert Tool - 18mm: T10179
Socket - Xzn 14: T10061
Counterhold - Multiple Use: T10172A
Transmission Support: 3282
Transmission Support - Mounting Plate 61: 3282/61
Engine Support Bridge: 10-222A

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Bolts - Transmission mount

Brief Description

Both the transmission and the bevel box are removed downward.

From above:

The battery, air filter housing and starter are removed. Coolant hoses are clamped off. Before removing the subframe mount, the engine and transmission must be supported.

From below:

The subframe is removed together with pendulum support and both control arms. The steering gear remains in the vehicle.

Both drive axles are disconnected 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.

Removing

-- Lift the vehicle, all four mounts from lifting platform at the same height.

NOTE:

To make it possible to rotate the driveshaft later so it can be loosened:

-- Move the selector lever into >>N<<.

-- Remove the bleeder -1- with the bleeder hose from the locking mechanism -arrow- of the battery tray -3-.

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-- 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 .

-- Pry out the selector lever cable -1- from the selector lever using the : 80-200 .

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-- Remove the bolts -2- and tie up the cable bracket -3- together with the selector lever cable.

-- Do not bend or kink the cable.

-- Remove the charge air pipe. Refer to OVERVIEW - CHARGE AIR SYSTEM .

NOTE:

The cooling system is under pressure when the engine is warm.

Before removing the coolant hoses on the transmission, cover the coolant expansion tank cap -arrow- with a cloth and carefully open.

Fig 1: Identifying Coolant Reservoir Cap

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-- Place a lint-free cloth on to transmission fluid cooler and transmission to absorb escaping coolant.

-- Clamp the coolant hoses with : 3094 and remove them from the transmission fluid cooler.

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-- Seal off the transmission fluid cooler connections with suitable sealing plugs taken from the : VAS6122 .

-- Disconnect the connector -1- for the Dual-Clutch Transmission Mechatronic -J743- in the direction of -arrow-.

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-- Remove the starter. Refer to STARTER, REMOVING AND INSTALLING .

It is advised to remove the >>lower<< bolt first.

-- Remove the upper engine/transmission connecting bolts with : T10179 .

Fig 2: Identifying Special Tool T10179

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Remove the bolt -arrow- with the : T10061 .

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-- If there are hose and cable connections located near the engine lifting eyes for the : 10-222A , these must now be removed.

-- Install the : 10-222A . Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION .

-- 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 wire and bracket from the front oil pan -arrows-.

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-- Route the wires near the transmission fluid pan upward and tie them secure.

-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

Fig 3: Disconnecting Connector From Oil Level Thermal Sensor G266

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-- Remove the subframe. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the drive axle heat shield from the bevel box. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

Fig 4: Identifying Right Drive Axle Heat Shield

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The right drive axle heat shield is attached with two nuts -arrows-.

-- Remove the left and right drive axle from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Secure both drive axles to the suspension strut using the : T10038 .

Fig 5: Identifying Ratchet Strap On Right Drive Axle

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Do not damage the surface protection of the shafts.

-- Remove the bolts -A and B- and remove the bevel box transmission support -1-.

Fig 6: Bracket Version 1 for Bevel Box

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-- Remove the bolts -arrows- from the bevel box and remove the heat shield -1-.

Fig 7: Identifying Heat Shield

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

Fig 8: Mark Position Of Driveshaft

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-- Remove the driveshaft from the bevel box -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Fig 9: Driveshaft Flexible Disc

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-- Counterhold at the rear final drive using : T10172A to loosen and tighten the driveshaft.

Fig 10: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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-- Push the front driveshaft all the way back and tie it up.

NOTE:

Sealing ring in driveshaft flange -arrow- must not be damaged during removal and installation.

Fig 11: Identifying Driveshaft Flange Shaft Seal

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Replace the driveshaft if it is damaged. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Install all driveshaft parts marked in relation to each other in same position when reinstalling.

-- Remove the bolts -arrows- of the transmission mounts for the transmission.

Fig 12: Identifying Transmission Mount To Transmission Mount Bracket Bolts

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-- Lower the engine/transmission on the transmission side to approximately to the dimension -a- using the spindles on the : 10-222A .

Fig 13: Identifying Measurement

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Dimension -a- = approximately 80 mm

-- Remove the remaining bolts except for one very accessible bolt between the engine and the transmission.

-- Remove the engine/transmission connecting bolt -arrow- next to the bevel gear -A-.

Fig 14: Identifying Engine/Transmission Connecting Bolt

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The : 3282 is equipped with the : 3282/61 to remove the transmission 0GC.

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-- Guide the : VAS6931 under transmission and support transmission. Do not lift.

The transmission is disconnected from the engine in this position.

-- Remove the last bolts between the engine and transmission.

-- Remove the transmission from the engine >>while also being careful of selector lever cable<< and lower the transmission.

Transmission, transporting. Refer to TRANSMISSION, TRANSPORTING .

Secure the transmission on the assembly stand. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

Install the transmission. Refer to TRANSMISSION, INSTALLING .