2.0L TDI CR

Transmission, Removing

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Bracket For Engine (10 - 222 A /1)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Transmission Support (3282)

• Shackle (10 - 222 A /12)

• Hose Clamps Up to 25 mm Dia. (3094)

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Hooks (3004)

• Pin (3282/29)

• Adjustment Plate (3282/42 A)

Removing

• Refer to => [ Repair Information ] 02EA Transmission.

• Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• Refer to => [ Transmission ] Transmission.

• When installing, bring all cable ties back to same positions.

- Turn off the ignition.


Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Remove molded tool insert under luggage compartment floor covering.

- Remove battery compartment cover - arrow -.






- Remove molded insert over battery.

- Disconnect the battery.






- Remove vacuum hose - 2 - on air duct hose.






- Remove air guide hose - 1 - on the throttle valve control module (J338).

- Disconnect the connector - 3 - on the Mass Airflow (MAF) sensor (G70).

- Remove upper section of air filter - arrow -.

- Remove filter insert.

- Remove air duct cover - 1 -.






- Unclip air duct - 2 -.

- Remove the lower section of the air filter - arrows -.






- Remove air filter housing - arrows -.






- Move the selector lever into P.






- Move the securing clamps - A - and remove.

- Press selector lever cable from the transmission shift lever - arrow - and place above.

- Remove the bolts - 1 -.

• Do not bend the selector lever cable.

• Ignore - B, C, D -.

- Disconnect the connectors - 1 - and - 3 -.






- Remove electrical wire - 2 - at starter solenoid switch.

- Remove the ground (GND) wire - 4 -.


There is a risk of destroying the control module (Mechatronic) with static discharge.

• Do not touch contacts in transmission connector with hands.

- To discharge static, touch vehicle ground with hand (without glove).

- Twist bayonet connection - 5 - of 20-pin connector to release it from transmission, and disconnect.

- Remove the starter.

- Mark coolant hoses to transmission fluid cooler to prevent mix-ups when installing.

- Remove the coolant hoses of the transmission fluid cooler with (3094) and remove from transmission oil cooler - A -.






- Seal any open lines and connections with a clean plug from the engine bung set (VAS 6122).

- Remove all engine/transmission bolts that can be reached from the top.






- If required, release the seal clip with the (80 - 200) and open up the seal.






- Disconnect any hoses and cables in the area of the (10-222 A) lifting eyes on the engine.






- Set (10 - 222 A) on the bolted fender flanges (vehicles until 05.2008) or the steel plate (vehicles after 05.2008), as shown in the illustration.

- Engage spindles in lifting eyes or at shackles.

- Preload the engine/transmission subassembly slightly using the spindle.

- Remove the noise insulation.






• Depending on the version, different noise insulation may be installed.

- Remove the wheel housing liner in the front section to the left and right.






• Depending on the version, different wheel housing liner may be installed.

- Remove the front wheels.

- If installed, remove guard plate at bottom of transmission - arrows -.






- Remove the bracket for the exhaust system - arrows -.






- Unclip the bracket - 2 - from the electrical wire to the oil level thermal sensor (G266) on the subframe.






- Remove bolts - 1 - and - 4 - and remove bracket.






- Remove nut - 1 - and press bracket - A - upward so that it does not hang when transmission is lowered.






• Bracket - A - is secured at front of transmission fluid pan.

- Disconnect exhaust system at double clamp - arrows -.






- Slide the clamping sleeve back.

- Tie up the exhaust system with a chain. To do this, insert (3004) into openings at vehicle floor (remove plug, if necessary).






• Do not bend the exhaust system flex joint more than 10° or it could be damaged.

- Remove the right drive axle heat shield from bevel box.






- Remove the left and right drive axles from the transmission flange.

- Lift up right drive axle and secure with wire.

- Remove the left drive axle from the wire and move it back.

- Identify position of flexible disc and bevel box flange to each other.






- Remove the driveshaft flexible disc at bevel box - arrows -.

• In order to loosen the bolts, hold a lever against the driveshaft flange/final drive.

- Slide front driveshaft tube as far back as possible.


• Sealing ring - arrow - in driveshaft flange must not be damaged when removing transmission. If seal is damaged, driveshaft must be replaced.

• When loosening pedal support/subframe bolts, engine/transmission assembly moves forward slightly.








- Remove the bolts - 2 - and - 3 -.






- Push the assembly forward slightly and remove the driveshaft from the bevel box.

- Remove the driveshaft above the bevel box and secure this from falling down.

- If equipped, remove left front level control system sensor (G78) - arrows -.






- Remove the subframe.







To remove control arm console, you must use the locating pins (T10096).

- Remove the left transverse link bracket form the body.

- Remove nuts - 1 - and bolts - 2 - at bevel gear transfer case bracket.






- Remove bracket - A - for bevel gear transfer case.

- Remove the bolts - 1 and 2 - and the transmission bracket - A -.






- Lower the engine/transmission assembly using the spindle.






• Dimension - a - between the transmission housing and transmission bearing must = 100 to 110 mm.






To remove the (3282) , the transmission support is equipped with the (3282/42 A) and positioned on the (V.A.G 1383 A).






- Align the arms of the transmission support to correspond with the holes in the (3282/42 A).

- Install the support elements on the (3282/42 A) as shown. The retaining plate with hole is used as a front support element.

- Place the (V.A.G 1383 A) under the vehicle.

• The arrow symbol on the adjustment plate points in the direction of travel.

- Align the (3282) so that it is parallel to the transmission.

- Screw the (3282/29) into the transmission.

- Attach the retaining plate with hole securely to the transmission - arrow - as shown.

- Insert the last support element in the transmission as shown.

- Support the transmission from underneath with the (V.A.G 1383 A).

- Remove the remaining bolts from transmission to engine connection.

- Remove the transmission from the alignment sleeves.

- Remove the transmission from engine at bevel box side and then at front side.

- Carefully lower transmission over (V.A.G 1383 A) , making sure no wires are pinched.

- Use spindles on the (3282) to adjust the position of the transmission while lowering it.