Transmission, Removing From Vehicles With 4-Cylinder Engine

Transmission, removing from vehicles with 4-cylinder engine - 6 Spd. M/T 01X Front Wheel Drive





Special tools, testers and auxiliary items required

^ Engine support bridge 10-222 A
^ Transmission support 3282
^ Adjustment plate 3282/43
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Engine/transmission jack V.A.G 1383 A

Special tools, testers and auxiliary items required





^ Insert pad for front fender T40045
^ Grease for clutch plate splines G000100
^ Copper grease Z381351TE

Procedure

Note:
^ All cable ties which are released or cut open during removal must be installed in the same position when installing.
^ Heat insulation sleeves removed during removal of transmission must be installed in the same position when installing.

CAUTION!
^ Follow steps required when disconnecting battery.





- With ignition switched off, disconnect battery Ground (GND) strap - arrow -.





- Remove engine cover - arrows -.





- Detach rubber seal from edges of wing mounting flanges.
- To avoid damaging edges of fenders with engine support bridge 10-222 A, insert wing compensation plates T40045 on both sides between fender mounting flange and body panel underneath.





- Set up engine support bridge 10-222 A with adapters 10-222/3 on fender mounting flanges.
- Engage spindles on engine lifting eyes as illustrated.
- Take up weight of engine using spindles.





- On vehicles equipped with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary heater to sound insulation.





- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.

Note:
^ - Item 3 - and - item B - can be disregarded.





- Remove bracket - arrow - for sound insulation.





- Unbolt heat shield - arrow - for drive axle (right side) from transmission.
- Unbolt drive axles (left and right) from transmission flange shafts.





Note:
^ The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10 degrees - otherwise it can be damaged.

- Separate exhaust system at clamp - arrow - and slide clamp to rear.





- Remove bolt - 1 - and nut - 2 - and detach retaining bracket for front exhaust pipe.





Cabriolet:

Note:
^ On Audi Cabriolet vehicles the following steps are required in order to remove the three bottom engine/transmission bolts:

- Unbolt torque reaction support - arrows -.





- Remove nuts - 1 - on left and right sides, and swivel stabilizer bar - 2 - downward.
- Remove nut - 3 - on left and right engine mountings until bottom of nut is flush with end of stud - arrow -.
- Use engine support bridge 10-222 A to lift engine just enough for nuts - 3 - to make contact with bottom surface of left and right consoles.





Continued for all vehicles:

- Remove three lower engine/transmission securing bolts - arrow -.

Cabriolet:
- Lower engine back down.





Continued for all vehicles:

- Detach starter from engine/transmission and secure if necessary.

Note:
^ Starter cables do not have to be disconnected.





- Drill a hole of 10.2 mm diameter - arrow - in supporting elements of transmission support 3282.





- To remove manual transmission 01X, set up transmission support 3282 with adjustment plate 3282/43 and place on engine/transmission jack V.A.G 1383 A.

Note:
^ The support elements 3282/49 - arrows A - and 3282/52 - arrows B - are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points toward the direction of travel.
^ Adjustment plate can only be installed in one position.





- Align adjustment plate parallel to transmission.
- Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt - arrow - on right side to 20 Nm.





- Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt - arrow - on left side to 20 Nm.





- Remove bolts - 1 - and bolts - 2 -.





- Remove nuts - arrows - and detach tunnel cross member.
- Lower transmission slightly using engine/transmission jack V.A.G 1383 A.





- Disconnect electrical connector - arrow - for back-up light switch F4 and move electrical wire clear.





- Remove connecting rod - 2 - for selector rod.
- Remove push rod - 1 - by using an 8 mm hex key when removing bolt.





- Remove nut - arrow - and detach selector shaft lever from selector shaft.





- Remove upper engine/transmission securing bolts - arrows 1 - and - arrows 2 -. Please note that retaining brackets for wires/lines and coolant pipe may be secured on bolts - arrows 2 - (important for installation).
- If installed, remove retaining clips/cable ties together with Lambda probe wiring from transmission.





- Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.
- Press transmission off dowel sleeves and lower carefully with engine/transmission jack V.A.G 1383 A just far enough to gain access to slave cylinder.

Note:
^ When lowering transmission, make sure hydraulic line to slave cylinder is not damaged.





- Remove slave cylinder from transmission - arrow - and secure with wire; do not open line/hose system.

CAUTION!
Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

- Lower transmission completely with engine/transmission jack V.A.G 1383 A.

Note:
^ When lowering transmission, make sure there is sufficient clearance to drive axles.

- Before carrying out assembly work, secure transmission to assembly stand, using holding fixture VW 540.





- If you will be installing a new transmission instead of the one removed, the transmission mounting has to be transferred to the new transmission - arrows -.

Install transmission.