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Transmission, Removing, 2.5L Engine

Special tools and workshop equipment required 

CAUTION:

When replacing the 09G AQ250 Gen III transmission with a new/remanufactured transmission, ensure that the oil cooler is ordered and replaced with the new transmission as the oil cooler does not come with the new transmission. Refer to the Parts Information.

Not replacing the oil cooler can cause failure of the new/remanufactured unit and contamination can enter the old transmission leading to misdiagnosis during analysis. Ensure the oil cooler stays on the transmission at all time unless it is absolutely necessary to remove it for diagnostic purposes. However, it should be reinstalled immediately afterwards.

Brief Description

The transmission is removed downward separately. The engine remains in the vehicle.

Remove the battery, the battery tray, and the engine cover with air filter >>from above<<. Engine and transmission are then supported so that the left transmission mount can be removed.

The noise insulation is removed >>from underneath<<. The drive axles are pulled off the transmission and then the left drive axle is removed. The transmission is lowered with the transmission jack.

The subframe is not removed.

Removing 

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

-- Disconnect the battery ground cable with the ignition switched off. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover with the air filter. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Disconnect the hoses -arrows- and remove the intake hose from the throttle valve.

Fig 1: Identifying Intake Hose And Throttle Valve Unit
GWWN37-10333Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the Transmission Control Module -J217- -3- at the top of the bracket -7- and remove it upward.

Fig 2: Identifying Bolts -1 And 6-, Connector -2-, Transmission Control Module -3- And Bracket -7-
GWWM10-10007Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the connector -2- and remove it from the Transmission Control Module -J217-.

-- Remove the bolts -1 and 6-.

-- Move the bracket -7- with the power steering fluid reservoir to the side. Pay attention to the wires -4 and 5-.

The hoses remain attached to the power steering fluid reservoir.

-- Remove the battery and the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

Fig 3: Identifying Battery Housing Bolts
GWWN34-11365Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To remove the selector lever cable from the transmission first release the cable in direction of -arrows 1- and then remove it from the cable mounting bracket in direction of -arrow 2-.

Fig 4: Identifying Cable Disengaged And Removed From Mounting Bracket
GWWN37-0324Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Do not use pliers because the tabs on the cable bracket could break off.

Do not bend or kink the selector lever cable.

-- Pry the selector lever cable -3- off the selector lever with a wrench -1-.

-- Disconnect the connector -4- from the Multifunction Transmission Range Switch -F125- and free up the wire on the bracket -2-.

Fig 5: Identifying Selector Lever Cable
GWWA10-10017Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the ground cable from the bolt -3- for the transmission bracket.

-- Disconnect the wires -1 and 2- from the starter and free them up.

Fig 6: Identifying Nut
GWWA10-10032Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bracket -1- from the upper starter bolt -arrow-.

Fig 7: Identifying Harness Retainer From Starter Bolt
GWWN37-10334Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt from the top of the starter.

NOTE:

Mark the ATF cooler coolant hoses to prevent confusing them when installing them later.

-- Clamp the coolant hoses to the ATF cooler with Hose Clamps - Up To 25mm: 3094  and Hose Clamps - Up To 40mm: 3093  .

Fig 8: Clamping Off Transmission Fluid Cooler Coolant Hoses
GWWN37-10488Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the spring clamps -A- and pull the coolant hoses -B and C- off the ATF cooler.

-- Seal the coolant hoses and connections with suitable plugs taken from the Engine Bung Set: VAS6122  .

-- Remove the upper transmission bolts -arrows- to the engine, for example, with a 12-point flex head socket wrench -A-.

Fig 9: Identifying Upper Transmission Engine Bolts And 12 Point Swivel Socket
GWWN37-10485Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

So that engine and transmission can be supported:

Fig 10: Identifying Wires, Engine And Transport Strap
GWWN37-10335Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the wires -1- from the transport strap -3-.

-- Remove the transport strap -3- from the engine -2- and pull it out of the eye -arrow-.

-- Insert a Engine/Gearbox Support Shackle (2 pc.): 10-222A/12  in >>this<< eye.

-- Remove the bolts -arrows- for the left and right lock carrier brackets. 

Fig 11: Locating Lock Carrier Bracket Bolts
GWWN10-10628Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the lower mounts on the Engine Support Bridge - Engine Support 28: 10-222A/28  and replace them with the Engine Support Bridge - Engine Support 28-2: 10-222A/28-2  .

Fig 12: Identifying Engine Support Bridge Adapter
GWWN10-10633Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the Engine Support Bridge - Engine Support 28: 10-222A/28  with the Engine Support Bridge - Engine Support 28-2: 10-222A/28-2  on the left and right of the lock carrier and secure it at the threaded holes for the lock carrier bracket -arrows-.

Fig 13: Locating Bracket Bolts
GWWN10-10634Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
CAUTION:

A second technician is required to mount the Engine Support Bridge: 10-222A  on the vehicle to prevent the Engine Support Bridge from tipping.

Mount the engine support bridge on the engine/transmission sub-assembly as follows:

Fig 14: Identifying Engine Support Bridge
GWWN10-10626Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Engine Support Bridge - Engine Support 31 - Adapter 2: 10-222A/31-2 
  2. Engine Support - Basic Set - Moveable Joint: T40091/3 
  3. Engine Support Bridge - Engine Support 31 - Adapter 1: 10-222A/31-1 
  4. Engine Support - Supplement Kit - Movable Joint: T40093A/4 
  5. Engine Support - Basic Set - Square Pipe: T40091/1 
  6. Engine Support Bridge - Engine Support 28: 10-222A/28  with Engine Support Bridge - Engine Support 28-2: 10-222A/28-2 
  7. Engine Support - Bracket w/Spindle and Hook: 10-222A/10 

-- First slide the Moveable Joints -2- onto the Square Pipe from the Engine Support Bridge: 10-222A  .

-- Position the Engine Support Bridge: 10-222A  on the suspension strut towers and have a second technician hold it to prevent it from falling over.

-- Push the left and right Square Pipe: T40091/1  -5- from the front through the Engine Support Bridge - Engine Support 28: 10-222A/28  -6- and position the Engine Support - Supplement Kit - Movable Joint: T40093A/4  -4- on each side.

-- Additionally attach the Engine Support - Bracket w/Spindle and Hook: 10-222A/10  -7- on the right Engine Support - Basic Set - Square Pipe: T40091/1  .

-- Push the Engine Support - Basic Set - Rail with Holes: T40091/2  -9- with the Engine Support - Supplement Kit - Mount: T40093A/5  -10- in the Engine Support - Supplement Kit - Movable Joint: T40093A/4  -4-.

Fig 15: Identifying Engine Support Bridge
GWWN10-10627Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Engine Support Bridge - Engine Support 31 - Adapter 2: 10-222A/31-2 
  2. Engine Support - Basic Set - Moveable Joint: T40091/3 
  3. Engine Support Bridge - Engine Support 31 - Adapter 1: 10-222A/31-1 
  4. Engine Support - Supplement Kit - Movable Joint: T40093A/4 
  5. Engine Support - Basic Set - Square Pipe: T40091/1 
  6. Engine Support Bridge - Engine Support 28: 10-222A/28  with Engine Support Bridge - Engine Support 28-2: 10-222A/28-2 
  7. Engine Support - Bracket w/Spindle and Hook: 10-222A/10 
  8. Engine Support - Automatic Transmission Hook: 10-222A/7 
  9. Engine Support - Basic Set - Rail with Holes: T40091/2 
  10. Engine Support - Supplement Kit - Mount 5: T40093A/5 
  11. Engine Support Bridge - Spindle: 10-222A/11 
  12. Engine/Gearbox Support Shackle (2 pc.): 10-222A/12 

-- Install the locking pins into the Engine Support - Basic Set - Rail with Holes: T40091/2  -9- and secure it with the cotter pins.

-- Tighten all the threaded connections on the Engine Support Bridge hand-tight. While doing so, adjust the height of the Engine Support Bridge parallel over the Engine Support Bridge - Engine Support 28: 10-222A/28  .

-- Extend the right Engine Support - Bracket w/Spindle and Hook: 10-222A/10  -7- with the Engine Support - Automatic Transmission Hook: 10-222A/7  -8-.

The hook on the Engine Support - Automatic Transmission Hook: 10-222A/7  points downward and will be engaged on cylinder block later.

-- Engage the left Engine Support Bridge - Spindle: 10-222A/11  -11- in the Engine/Gearbox Support Shackle (2 pc.): 10-222A/12  -12-.

-- Press the brake and remove left bolt from the drive axle -arrow- (a second technician will be needed).

Fig 16: Identifying Drive Axle Bolt
GWWN37-0095Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

From now on do not let the vehicle touch the ground. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Raise the vehicle and remove the front wheels.

-- Remove the noise insulation.

-- Remove the left and right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Separate the exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe. Refer to OVERVIEW - MUFFLER .

-- Remove the control arms from the wheel bearing housing on both sides -arrows-.

Fig 17: Ball Joint To Lower Control Arm Nuts
GWWN34-11370Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If equipped, remove the heat shield above the right drive axle -arrows-.

Fig 18: Drive Axle Heat Shield
GWWN34-11369Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the right drive axle out of the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Fig 19: Attaching T10161 Between Transmission Housing And Triple Roller Joint
GWWA40-0533Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Position the right drive axle as high as possible and secure it in this position.

Fig 20: Identifying Ratchet Strap On Right Drive Axle
GWWN37-10433Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -1 and 2- from the transmission.

Fig 21: Identifying Electrical Connectors At Transmission
GWWN37-10337Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the power steering line clamps from the transmission -arrows-.

Fig 22: Expansion Hose Routing On Automatic Transmission
GWWM48-10027Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connector from the bracket under the starter -1- and then disconnect it.

-- Remove bracket from lower starter bolt.

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

Fig 23: Identifying Connector Under Starter
GWWN37-10332Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn the cap -1- in direction of -arrow- and remove it.

Fig 24: Identifying Cover Cap
GWWN37-10338Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the six -converter nuts- with the Socket - Sw15: V/175  .

Fig 25: Locating Converter Nuts
GWWN37-10124Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To do so, turn the engine 60° further in the direction of engine rotation in direction of -arrow- using the Crankshaft Adapter: T03003  .

Fig 26: Identifying Crankshaft Adapter T03003
GWWN37-10489Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

If all six torque converter nuts are not removed, the torque converter will be pulled out when removing the transmission from the engine!

Counterhold on the belt pulley/vibration damper using the Crankshaft Adapter: T03003  when loosening the torque converter nuts.

-- Remove the selector lever cable bracket from the transmission.

Fig 27: Identifying Selector Lever Cable Retainer And Bolts
GWWN37-10203Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the pendulum support: First bolt -A- then bolts -B-.

Fig 28: Identifying Pendulum Support And Bolts
GWWN34-10007Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Engage the Engine Support - Automatic Transmission Hook: 10-222A/7  on the cylinder block.

Fig 29: Adapter 10 - 222 A /7 Engaged On Engine Block
GWWN37-10339Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tension the Engine Support - Bracket w/Spindle and Hook: 10-222A/10  -7- one turn (more is not necessary).

Fig 30: Identifying Engine Support Bridge
GWWN10-10627Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the engine and transmission with the Engine Support Bridge - Spindle: 10-222A/11  -11-. Do not lift.

-- Remove the transmission mount bolts -2- to the transmission bracket -A- and remove the transmission bracket bolts -1- to the transmission.

Fig 31: Transmission Console And Bolts
GWWA37-0570Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transmission bracket -A-. To do so, slightly lower the engine with the transmission using the spindles of the Engine Support Bridge: 10-222A  .

Four turns should be sufficient.

-- Remove the lower connecting bolts between the engine and the transmission.

-- For safety, leave one bolt installed that is easily accessible.

-- Place the Transmission Support: 3282  on the Engine and Gearbox Jack: VAS6931  .

Fig 32: Identifying V.A.G. Transmission Support Tool 3282
GWWA37-0574Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the Transmission Support - Mounting Plate 36: 3282/36  on the Transmission Support: 3282  (the Mounting Plate only fits in one position).

-- Align the arms of the Transmission Support so that they match up with the holes in the Mounting Plate.

-- Install support elements as shown on Mounting Plate.

-- Move the Engine and Gearbox Jack: VAS6931  with the Transmission Support: 3282  under the transmission and support the transmission.

-- Secure the transmission to the Transmission Support: 3282  using the nut -1- on the double bolt.

-- Now remove the last transmission/engine bolt.

-- Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate.

Fig 33: Press Torque Converter Against ATF Pump
GWWN37-0792Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the transmission past the power steering line and past the subframe when lowering it. Adjust the Transmission Support: 3282  slightly, if necessary.

NOTE:

Be careful not to damage the vacuum line between the vacuum pump and the brake booster when removing and installing the transmission.

Be careful not to damage the connector on the front of the transmission during removal and installation, for example, by coming in contact with the power steering line. Replace the wiring harness in the transmission if the connector gets damaged. Refer to OVERVIEW - VALVE BODY, TRANSMISSION CODE MAN, PDW .

Pay attention to the torque converter. It must be removed together with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

Fig 34: Converter Secured From Falling Out Using A Wire
GWWN37-10122Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The cable bracket and the selector lever cable bracket must be replaced when installing a new transmission.

Fig 35: Cable Bracket And Selector Level With Torque Specifications
GWWN37-10294Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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