Transmission, Removing (Vehicles With 4-Cylinder Engine)
Transmission, removing (vehicles with 4-cylinder engine) - 6 Spd. Manual Transmission 02X All Wheel Drive
Special tools, testers and auxiliary items required
^ Support bracket 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 -.
Vehicles with 2.0 liter turbo engine:
- Remove engine cover panel - arrows -.
- 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).
- Remove rubber seal from edges of fenders mounting flanges.
- To avoid damaging edges of the fender panels use support bracket 10-222 A, insert insert pad for front fender T40045 on both sides between the fender mounting flange and the body panel underneath.
- Set up support bracket 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 bolts - arrows - securing exhaust pipe of auxiliary heater to sound insulation.
- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
- If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.
- Detach bracket - arrow - for sound insulation.
- Remove heat shield - arrows - for drive axle (right-side).
- Remove drive axles (left and right) from transmission flange shafts.
Make sure you do not damage surface coating on drive axles.
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.
- If installed, remove heat shield for drive axle - arrows -.
- Remove bolts - arrows - at transmission/drive shaft flange.
- Slide drive shaft together towards rear final drive. The constant velocity joints can be moved axially.
- Tie drive shaft to side.
Cabriolet:
Note:
^ On Audi Cabriolet vehicles the following additional steps are required in order to remove the three bottom engine/transmission bolts:
- Remove torque reaction support - arrows -.
- Unscrew nuts - 1 - on left and right sides, and swivel anti-roll bar - 2 - downwards.
- Loosen nut - 3 - on left and right engine mountings until bottom of nut is flush with stud - arrow -.
- Use support bracket 10 - 222 A to lift engine just enough for nuts - 3 - to make contact with left and right console.
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 02X, 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 the left side of the transmission, as shown in illustration. Tighten bolt - arrow on right side - to 20 Nm.
- Secure supporting elements to the right side of the transmission, as shown in illustration. Tighten bolt - arrow on left side - to 20 Nm.
- First remove bolts - 1 - and then 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 unscrewing bolt.
- Remove nut - arrow - and detach selector shaft lever from selector shaft.
- Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.
- Press transmission off dowel sleeves and lower carefully using 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.
- If installed, remove retaining clips/cable ties together with Lambda probe wires from top of transmission.
- Lower transmission.
Note:
^ When lowering transmission, make sure there is sufficient clearance to drive shafts.
- Before performing assembly work, secure transmission to assembly stand, using holding fixture VW 540.
- If installing a new transmission instead of the one removed, the transmission mounting has to be transferred to new transmission - arrows -.
Installing transmission