Transmission, Removing
Special tools and workshop equipment required
- Engine Support Bridge: 10-222A
- Engine Support Bridge - Engine Support 29: 10-222A/29
- Engine Support Bridge - Engine Support 18: 10-222A/18
- Engine/Gearbox Support Shackle (2pc.): 10-222A/12
- Transmission Support - Pins 29: 3282/29
- Transmission Support: 3282
- Transmission Support - Mounting Plate 39: 3282/39
- Support Elements for transmission (determine when mounting the Mounting Plate on the Transmission Support)
- Engine and Gearbox Jack: VAS6931
- Torque Wrench 1331 5-50Nm: VAG1331
- Torque Wrench 1332 40-200Nm: VAG1332
- Transmission Support Jig: 3336 for transporting the transmission
- Lubricating Grease for Clutch Plate Splines
- Determine the shift mechanism grease using the Parts Information.
- Spindle from the Seal Installer - Driver Set: 3066 or M8 x 105 bolt
- Seal Installer - One-Piece Seal: T10148
- Square Pipe: T40091/1 (quantity: 2)
- Engine Support - Joint Fixture: T40091/3 (quantity: 2)
- Spindle: T40093/3 (quantity: 2) from the Engine Support Supplement Set: T40093B
- Engine Support Brackets: T40093/3-6 (quantity: 2)
- or Engine Support Brackets: T40093/3-6A (quantity: 2)
Engine Support Brackets T40093/3-6, Checking and Replacing if Necessary
-- Disconnect the marked area if necessary.
-- Round off the front edges.
-- Protect the Bracket against corrosion.
-- Then mark the : T40093/3-6 with : T40093/3-6A .
The : 10-222A and the : T40093/3-6A will be mounted on the longitudinal members later in the procedure.
- So that the longitudinal members will not be damaged, tape around the : T40093/3-6A in the front area with cloth tape. Refer to the Parts Information (Chemical Materials).
-- Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
-- Remove the bolts -arrows- and battery tray -1-. Refer to BATTERY TRAY, REMOVING AND INSTALLING .
-- Remove the cable retainer from the selector cable. Refer to Figure.
-- Remove the clip -arrow 1- and then remove the relay lever and the cable retainer.
-- Remove the shift cable lock washer -arrow 2- from the selector lever -A-.
-- Remove the shift cable from the gearshift lever pins.
-- Remove the nut -arrow 3- and then remove the transmission shift lever -A-.
-- Remove the cable bracket from the transmission -arrows-.
-- Tie up the shift cable and the selector cable.
-- If equipped, remove the bracket -B- from the transmission and remove it from the hose/line assembly -A-.
-- Remove the transmission support -arrows A-.
-- Remove clutch slave cylinder -arrow B- and lay aside, secure with wire, do not open line system.
The clutch slave cylinder could be damaged.
- If the clutch slave cylinder is removed from the transmission with pipe/hose line still connected, do not press the clutch pedal.
-- Remove the ground cable upward from the engine/transmission connecting bolt or from the upper starter bolt.
-- Disconnect the connector -arrow 1- from the Back-Up Lamp Switch -F4-.
-- Remove the connector -arrow 2- and wire -arrow 3- from the starter.
-- Remove the upper bolt from the starter.
-- Remove the upper engine/transmission bolts.
-- If there are hose and cable connections located near the engine lifting eyes for the : 10-222A , these must be removed.
-- Mount the : 10-222A as follows:
The following are needed:
- Engine Support Bridge - Engine Support 18: 10-222A/18
- Engine/Gearbox Support Shackle: 10-222A/12 , quantity: 2 (required if the Spindles from the Engine Support Bridge cannot be engaged in the engine lifting eyes).
- Engine Support Bridge - Engine Support 29: 10-222A/29 (quantity: 2)
- Square Pipe: T40091/1 (quantity: 2)
- Engine Support - Joint Fixture: T40091/3 (quantity: 2)
- Spindle: T40093 /3 (quantity: 2)
- Engine Support Brackets: T40093/3-6A (quantity: 2)
-- On both sides of the vehicle, insert the : 10-222A/29 between the fender bolting edge and the fender bolting plate underneath it.
- Installation position:
"L" = -1- Adapter is inserted on the "right" side of the vehicle (Adapter locks in place in the fender opening).
"R" (not illustrated here), Adapter is installed on the "left" side of the vehicle.
The arrow -2- on the : 10-222A/29 always points in the direction of travel.
-- Slide the : 10-222A/18 and the two : T40091/3 onto the : 10-222A .
-- Tighten the : 10-222A on the : 10-222A/29 .
-A- = : T40093/3-6A (see the next illustration).
-- If present, remove wires from the front area of both longitudinal members -arrow-. Do not disconnect the line system
-- Place the : T40093/3-6A on both longitudinal members (the right longitudinal member is illustrated here).
-- If necessary, carefully unclip the A/C system pipe in the front area. Do not disconnect the line system. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .
- The : T40093/3-6A lock to the respective pin -A- behind the tab on the longitudinal member -arrow-.
- Place the : T40093/3-6A on the left longitudinal member directly behind the filler tube for the washer fluid reservoir -B-.
- If necessary, push the : T40093/3-6A into position.
-- Install the : T40093/3 .
-- Connect the : T40093/3 to the : 10-222A using the : T40091/1 and tension (see the previous illustration).
The : T40091/1 must not touch the windshield.
The : 10-222A/18 must not lie on the windshield wiper arm.
-- If necessary, the Spindles can then be engaged in the engine lifting eyes using the : 10-222A/12 .
-- Lightly pretension the engine/transmission assembly and Engine Support Bridge using the Spindles.
-- Raise the vehicle and remove the left front wheel.
-- 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 nut -arrow- and then remove the wire bracket.
-- Remove the starter. Refer to STARTER, REMOVING AND INSTALLING .
-- Remove all wires from the transmission.
-- Transmission for vehicles with Start/Stop System: disconnect the connector -arrow- from the Transmission Neutral Position Sensor -G701-.
-- Remove the nuts -1- from both sides of the coupling rod -3-.
-- Remove the coupling rod -3- from both sides of the stabilizer bar -2-.
-- If equipped, remove the Left Front Level Control System Sensor -G78- from the lower control arm. Refer to LEFT FRONT LEVEL CONTROL SYSTEM SENSOR -G78- /RIGHT FRONT LEVEL CONTROL SENSOR -G289-, REMOVING AND INSTALLING .
-- If equipped, remove the drive axle heat shield -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 .
-- Remove the engine/transmission connecting bolt -A- above the right flange shaft.
-- Remove the right flange shaft bolt -arrow- -B-. Insert two bolts in the flange and counterhold the flange shaft with the extractor lever.
Check the seal for leaks before removing the flange shaft. If the seal has leaks, replace it when installing. Refer to RIGHT SEAL, REPLACING .
If transmission fluid leaks out while removing the flange shaft, the transmission fluid must be drained and refilled on the installed transmission and installed flange shaft. Refer to TRANSMISSION FLUID .
-- Remove the right flange shaft.
-- Install the spindle -A- from the : 3066 in the threaded piece on the differential.
-- Insert the : T10148 and secure with the nut -B-.
The : T10148 protects the right seal and the transmission from dirt.
An M8 x 105 mm bolt may be installed by hand into the differential threaded piece instead of a spindle -A-.
Risk of damaging the decoupling element.
- Pay attention to OVERVIEW - EMISSIONS CONTROL SYSTEM .
-- Remove the bolts -arrows- for the exhaust system bracket from the subframe.
-- Separate the exhaust system at the clamping sleeve -arrow-. Refer to OVERVIEW - MUFFLER .
-- Remove the bolts -1 through 3- and remove the pendulum support.
-- If present, remove the nut -arrow- and ground cable.
-- Remove the left subframe mount hex bolts -arrows- from the transmission mounting.
-- Lower the transmission (the transmission moves toward the front).
- Dimension -a- = approximately 50 mm
-- Remove the transmission bracket -A- -arrows-.
Set up the : 3282 with the : 3282/39 to remove the transmission "02S".
-- Insert the : 3282 into the : VAS6931 .
-- Align the arms of the Transmission Support so that they align with the holes in the Adjustment Plate.
-- Install the Mounting Elements -A- and -C-, on the Adjusting Plate, as illustrated.
-- Position the Engine and Transmission Jack under the vehicle. The arrow symbol -B- on the Adjusting Plate points in the direction of travel.
-- Align the adjusting plate so that it is parallel to the transmission and secure the safety support to the transmission.
-- Install the : 3282/29 into the rear hole for the pendulum support bolt on the transmission.
-- Remove the engine/transmission bolt -arrow- under the right flange shaft.
-- Remove the lower engine/transmission connecting bolts.
-- Remove the transmission from the alignment bushings and carefully move it toward the subframe.
-- Tip the transmission forward in the direction of -arrow- using the spindle on the : 3282 .
-- Carefully push the engine forward slightly with a second technician.
-- Carefully lower the transmission with the : VAS6931 , while making sure that the right flange shaft seal -1- is guided through without any damage to the pressure plate -arrow-.
-- Prefill the left flange shaft -B- as shown on the subframe -arrow-. Move the Engine and Gearbox Jack with the transmission to the front.
-- When lowering, change the transmission position using the spindles on the : 3282 .
Pay attention to all of the lines when lowering the transmission.
-- If necessary, re-insert the right flange shaft and tighten the countersunk bolt -arrow-.
Tightening Specifications
- Refer to OVERVIEW - DIFFERENTIAL