Transmission (Vehicles With 4 Cylinder Engines), Removing
Transmission (vehicles with 4 cylinder engines), removing, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Engine support bridge 10-222 A
^ Hose clamps up to 25 mm dia. 3094 (3x)
^ Hooks 3004 (3x)
^ Transmission support 3282
^ Adjustment plate 3282/27
^ Engine/transmission jack V.A.G 1383 A
^ Chain (2x)
Work procedure
Note: All cable ties opened or cut during transmission removal must be reinstalled at the same locations.
- Bring shift lever into idle position.
- To remove expanding clips - 1 - at lock carrier, press in pin - 2 - approx. 4 mm. Remove expanding clip upward.
- Remove covers - 1 - and - 2 - above lock carrier and battery - arrows -.
CAUTION! Observe safety precautions with disconnecting battery.
- With ignition switched off, disconnect battery Ground (GND) strap.
TT Roadster:
CAUTION! Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
All:
- Remove engine cover - 1 - above cylinder head cover - upper arrows -.
- Remove air guide hose from Throttle Valve Control Module J338, to do so remove hose clamp - 4 -.
- Disconnect electrical harness connector at Mass Air Flow (MAF) Sensor G70 - 1 -.
- Disconnect hose - 5 - from air filter housing if installed.
- Remove bolts - 2 - and - 3 -.
- Remove air filter housing.
- Remove battery and battery holder - arrows -.
- Unscrew cable mounting bracket on transmission - arrows -.
Vehicles up to 06.2001:
CAUTION! Cable locking mechanisms must not be removed from shift rod lever and linkage lever. If cable locking mechanisms were removed, they must be replaced.
- Disengage cable locking mechanism for selector cable, to do so, press casing in direction of - arrow 1 - to stop and engage by turning left in direction of - arrow 2 -.
- Pull selector cable out of cable locking mechanism.
Vehicles as of 07.2001:
- Remove locking washer - arrow 2 - and remove linkage lever - A - together with selector cable.
All:
- Remove nut - arrow 1 - for power steering pressure line.
- Remove nut - arrow 3 - and remove shift rod lever - B - together with shift cable.
Note: If necessary, use puller Kukko 20-10 to pull off.
- Tie up shift cable, shift rod lever and selector cable.
- Disconnect electrical harness connector from Speedometer Vehicle Speed Sensor (VSS) G22 - arrow -.
- Remove Ground (GND) strap - 1 -.
- Disconnect electrical harness connector - 3 - from starter. Electrical wire - 4 - remains connected.
- Disconnect electrical harness connector - 2 - and remove from bracket.
- Detach wires from bracket at starter and lay aside
- Remove bracket.
- Remove upper mounting bolt from starter.
- Remove engine/transmission connecting bolts accessible from above.
Vehicles with 2 charge air coolers:
Note: Mark direction of rotation of ribbed belt using chalk or felt-tip marker before removing. Reversing the direction of rotation of a run-in belt can destroy the belt.
- Move tensioner in direction of - arrow - to release tension on ribbed belt.
- Remove ribbed belt.
Vehicles with 1 charge air cooler:
- Remove air guide pipe to charge air cooler on lower right of long-member - arrows -.
All:
- Remove both front wheels.
TT Coupe:
- Remove sound insulation on center mounting parts - 1 to 3 -.
TT Roadster:
- Loosen mounting parts in wheel housing at left and right.
- Remove bolts - arrows 1 to 3 -.
Note: Disregard - arrows A and B -.
All:
- Remove left sound insulation - arrows -.
- Remove right sound insulation - arrows -.
Vehicles with 2 charge air coolers and TT Roadster:
- Remove tubular cross member - arrows -.
Vehicles with 2 charge air coolers:
- Remove power steering pump pulley, counterhold with hex socket wrench.
All:
- Disconnect inlet and pressure line at power steering pump using Hose clamps up to 25 mm dia. 3094.
- Disconnect electrical harness connector - 1 - at pressure switch for power steering.
- Remove pressure line - 2 - at power steering pump.
- Disconnect power steering line from transmission - arrows - and remove metal nut from transmission.
Note: If installed, remove additional bracket for line.
- Remove lower starter mounting bolt and starter.
- Use Hose clamps up to 25 mm dia. 3094 to clamp pressure line to clutch slave cylinder.
- Pull retainer upward - arrow - and pull pressure line - 1 - out of hose connection.
CAUTION! Clutch pedal must not be operated after disconnecting pressure line to clutch slave cylinder.
- Disconnect electrical harness connector at Back-Up Light Switch F4 - 2 -.
- Disconnect exhaust system at double clamp - arrows -.
- Slide double clamp toward rear.
- Tie up exhaust system using a chain. To do this, insert hook 3004 into openings at vehicle floor (remove plug, if necessary).
Note: Flex joint of exhaust system must not be bent more than 10°, otherwise it may be damaged.
- Mark position of driveshaft to flexible disc at bevel gear transfer case.
- Unbolt driveshaft from flexible disc at bevel gear transfer case - arrows -.
Note: To remove bolts counterhold at triangular flange using a lever.
- Press driveshaft horizontally toward rear as far as possible.
Note: After removing bolts - A - (following illustration N34-0712), engine/transmission assembly moves slightly forward.
CAUTION! Make sure not to damage seal - arrow - in flange of drive axle when removing and installing. If seals are damaged, driveshaft must be replaced.
- First remove bolts - A - and then bolts - B - and remove pendulum support.
- Carefully press engine/transmission assembly forward.
TT Roadster:
- Remove 8 bolts - 1 - with locking washers - 2 - and remove diagonal members.
All:
- If installed, remove front exhaust system bracket - arrow - from subframe.
- Remove bolts - 2 - for steering gear.
- Pry off steering gear from subframe (alignment bushing).
- Place engine/transmission jack V.A.G 1383 A with universal mount V.A.G 1359/2 under subframe.
- Remove bolts - 1 - and - 3 - for subframe.
- Carefully lower subframe and let hang on ball joints and coupling rods, press steering gear upward while doing so.
- Tie up steering gear.
- Remove driveshafts from transmission drive flanges and lay behind on subframe without damaging protective coating.
- Tie subframe toward rear using a chain, insert hook 3004 into opening at vehicle floor (remove plug, if necessary).
- Remove heat shield for right driveshaft from bevel gear transfer case - arrows -.
Vehicles with cast bracket for bevel gear transfer case:
- Remove bolts - A to C - at bevel gear transfer case bracket.
Note: The bracket cannot be removed at this stage. Leave bracket in installed position.
Vehicles with metal bracket for bevel gear transfer case:
- Remove bolts - A to C - and remove bevel gear transfer case bracket.
All:
Note: The small cover plate - 2 - is seated behind the bevel gear transfer case and is not visible if bevel gear transfer case is installed. Illustration is shown with transmission removed.
- Remove bolt - 1 - 10 mm and remove cover plate for flywheel behind bevel gear transfer case.
- Place Engine Support Bridge 10-222 A with Bracket for Engine 10-222 A/1 on upper edge of web plate - arrows -.
- Pretension engine/transmission assembly somewhat using spindle.
- Remove left transmission support, to do so remove bolts - 1 - and - 2 -.
- Lower engine/transmission assembly at spindle a short distance.
^ Between transmission housing and transmission bearing dimension - a - must be = 100 to 110 mm.
Transmission support 3282 is attached to Adjustment Plate 3282/27 for removing manual transmission 02M.
A - Attachments
B - Arrow in direction of travel
- Assemble engine/transmission jack V.A.G 1383 A as follows:
- Set Adjustment Plate 3282/27 on to Transmission Support 3282 (adjustment plate only fits in one position).
- Bolt attachments as labeled on adjustment plate.
- Align transmission support arms to correspond with holes in Adjustment Plate 3282/27.
- Place engine/transmission jack V.A.G 1383 A under vehicle, arrow symbol on adjustment plate points in direction of travel/vehicle.
- Align adjustment plate parallel to transmission.
- Secure attachment to transmission using bolt M8x25 - arrow -.
- Remove bolt - arrow - above bevel gear transfer case.
- Remove engine/transmission connecting bolts accessible from bottom.
- Press transmission off alignment bushings.
- Remove bracket for bevel gear transfer case.
- Remove transmission from engine on bevel gear transfer case side first and then on front side.
- Lower transmission carefully.