Transmission, Removing

Fig 1: Identifying Special Tools And Workshop Equipment

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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: 10-222A/12 (quantity: 2)
Transmission Support - Pins 29: 3282/29
Transmission Support: 3282

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS6931

Fig 2: Engine and Gearbox Jack VAS6931 or VAG1383A
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Transmission Support - Mounting Plate 39: 3282/39

Fig 3: Identifying Adjustment Plate
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-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING (1.5L) .

-- Remove the battery and the battery tray -1- -arrows-. Refer to BATTERY, REMOVING AND INSTALLING .

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-- 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.

Fig 4: Identifying Transmission Shift Lever -A- And Nut -Arrow 3-

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-- 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-.

Fig 5: Identifying Cable Bracket Support Bolts

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-- 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-.

Fig 6: Identifying Transmission Support And Slave Cylinder

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-- Remove clutch slave cylinder -arrow B- and lay aside, secure with wire, do not open line system.

CAUTION:

The clutch slave cylinder could be damaged.

As soon as the clutch slave cylinder together with the connected hose/line assembly is dismounted from the transmission, the clutch pedal must not be operated anymore.

-- Remove the ground cable upward from the engine/transmission connecting bolt or from the upper starter bolt.

Fig 7: Identifying Back-Up Light Switch And Starter Connectors

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-- 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 Engine Support Bridge: 10-222A , these must be removed.

-- Support the engine and transmission in their installation position. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION .

-- 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 OVERVIEW - FRONT WHEEL HOUSING LINER .

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

-- Remove all wires from the transmission.

Fig 8: Connect The Connector

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-- 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-.

Fig 9: Coupling Rod And Nuts And Stabilizer Bar

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-- 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 OVERVIEW - FRONT LEVEL CONTROL SYSTEM SENSOR .

Fig 10: Identifying Left Front Level Control System Sensor

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-- If equipped, remove the drive axle heat shield -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

Fig 11: Drive Axle Heat Shield

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-- 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.

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-- Remove the right flange shaft bolt -arrow- -B-. Insert two bolts in the flange and counterhold the flange shaft with the extractor lever.

NOTE:

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 Seal Installer - Driver Set: 3066 in the threaded piece on the differential.

Fig 12: Identifying Thrust Piece And Nut

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-- Insert the Seal Installer - One-Piece Seal: T10148 and secure with the nut -B-.

NOTE:

The Seal Installer - One-Piece Seal: 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-.

CAUTION:

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.

Fig 13: Exhaust System Bracket

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-- Separate the exhaust system at the clamping sleeve -arrow-. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM .

Fig 14: Locating Clamping Sleeve Screws

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-- Remove the pendulum support.

Fig 15: Identifying Pendulum Support

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-- If present, remove the nut -arrow- and ground cable.

Fig 16: Identifying Nut

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-- Remove the left subframe mount hex bolts -arrows- from the transmission mounting.

Fig 17: Identifying Left Subframe Mount

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-- Lower the transmission (the transmission moves toward the front).

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Dimension -a- = approximately 50 mm

-- Remove the transmission bracket -A- -arrows-.

Fig 18: Identifying Transmission Plate Bolts

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Set up the Transmission Support: 3282 with the Transmission Support - Mounting Plate 39: 3282/39 to remove the transmission "02S".

Fig 19: Identifying Transmission Support Adjustment Plate

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-- Insert the Transmission Support: 3282 into the Engine and Gearbox Jack: 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.

Fig 20: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Supports On Transmission

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-- Install the Transmission Support - Pins 29: 3282/29 into the rear hole for the pendulum support bolt on the transmission.

Fig 21: Identifying Engine/Transmission Connecting Bolt

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-- 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.

Fig 22: Identifying Transmission Inclined With Spindles Of Transmission Support 3282

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-- Tip the transmission forward in the direction of -arrow- using the spindle on the Transmission Support: 3282 .

Fig 23: Identifying Engine/Transmission Jack

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-- Carefully push the engine forward slightly with a second technician.

-- Carefully lower the transmission with the Engine and Gearbox Jack: VAS6931 , while making sure that the right flange shaft seal -1- is guided through without any damage to the pressure plate -arrow-.

Fig 24: Identifying Left Flange Shaft

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-- Prefill the left flange shaft -B- as shown on the subframe -arrow-. Move the Engine and Gearbox Jack with the transmission to the front.

Fig 25: Identifying Right Flange Shaft And Hole

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-- When lowering, change the transmission position using the spindles on the Transmission Support: 3282 .

NOTE:

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-.

Fig 26: Locating Right Flange Shaft Bolt

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Tightening Specifications

Refer to OVERVIEW - DIFFERENTIAL