FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Volkswagen >> 2004 >> New Beetle Convertible (1Y1) L4-1.8L Turbo (AWV) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> 6 Speed Automatic 09G >> Transmission, Removing and Installing

Transmission, Removing and Installing


Transmission, removing and installing
Special tools and equipment





^ 10-222 A Support assembly
^ 10-222 A/8 Adapter
^ 10-22212 A Shackle
^ 3094 Hose clamps
^ 3282 Transmission bracket
^ 3282/36 Adapter plate

Special tools and equipment





^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383 A Engine/Transmission jack
^ V/175 Socket insert

Removing

Note: All cable ties which are opened or cut open when removing the transmission must be replaced in the same position when installing the transmission.

- Move selector lever to position "N".
- Remove cover from engine.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove power steering reservoir from battery carrier. Do not bend hoses when doing this.
- Tie reservoir up on lock carrier.
- Remove battery and battery carrier.

Note: Observe the required measures before disconnecting the battery.





- Pull intake hose -1- and connector -2- off Mass Air Flow (MAP) sensor.
- Pull secondary air pump hose -3- off air cleaner housing.
- Remove bolts -4-, -5- and -6-.
- Remove air cleaner complete.





- Press selector lever cable -1- off selector shaft lever -6- with an open end wrench.

Note: Do not loosen bolt -2-.

- Remove both bolts -3-.
- Release selector lever cable from clip on transmission -4- and tie up high.

Note: Do not kink selector lever cable.

- Pull connector -5- off multi-function switch.
- Disconnect connections on starter.





- Remove starter -A-.
- Disconnect connectors -B- (14-pin) and -C- (8-pin) from transmission.

Note: If the connectors -B- or-C-, which are screwed to the transmission, are damaged/destroyed during removal or for any other reason, the respective wiring harness (8-pin or 14-pin) connector must also be replaced).





- Clamp off ATF cooler hoses with clamp 3094 and disconnect from ATF cooler.
- Seal off ATF cooler with clean plugs.
- Remove Ground strap from engine/transmission upper connection bolt.
- Remove upper bolts that connect engine to transmission.
- Erect support assembly 10-222 A with adapters 10-222 A/8.





Note: Do not seat adapter 10-222 A/8 on securing bolts for front end/fender.

- When hoses or wiring are still located in vicinity of engine lifting eyes for support assembly 10-222 A they must be removed now.
- Secure left-hand spindle (transmission side) to engine lifting eye using shackle 10-222 A/12 if necessary.
- Pretension engine/transmission assembly lightly by means of spindles.
- Remove both front wheels.





- Remove sound insulation (arrows).
- Remove left-hand sound insulation.





- Remove sound insulation retainer -1-.
- Remove power steering line -2- on transmission (arrows -A-).
- Remove left side axle shaft -3- complete.





- Mark installation position of ball joint bolts (arrows) on control arm.
- Remove bolts (arrows).
- Disconnect coupling rod -A- from control arm.

Note:
^ This work sequence is necessary so that there is no requirement to disconnect the axle shaft from the wheel bearing (wheel hub).
^ The right side axle shaft must only be disconnected from the transmission.





- Remove right hand inner constant velocity joint protective cover -A from engine (arrows) if part of original equipment.
- Disconnect right side axle shaft -B- from transmission (direction of arrow).

Note:
^ There is no separate flange shaft in the transmission, the axle shaft is inserted directly into the transmission.
^ Special tool T10161 must be used to pry the axle shaft out of the transmission. When using other tools to remove the axle shaft, such as a screwdriver or an assembly lever, the transmission or the axle shaft will be damaged and must therefore be replaced.





- Raise right side axle shaft -B- and secure (tie up).
- Unclip cap for torque converter nuts cover -A-.





- Remove nuts (arrow) from torque converter (Qty. 6) using socket insert V/ 175.
Turn crankcase 60° further in each case.

Note: When all 6 nuts are not removed from the torque converter, the torque converter will be pulled out when removing the transmission from the engine.

- Disconnect exhaust system at double clamp after front exhaust pipe
- Tie exhaust system up.

Note: The flexible element of the exhaust system must not be bent more than 10° or it will be damaged.





- Remove transmission bracket -A- (remove bolts -1- and -2-).
- Carefully tilt engine with transmission. To do this lower left-hand spindle (transmission side) on support assembly 10-222 A approx. 50 mm.
The transmission support 3282 is set up with adjusting plate 3282/36 for removing the automatic transmission COG.
- Align arms of transmission mounting with holes in adjusting plate.
- Screw in mounting elements as shown on adjusting plate 3282/36.





- Position transmission jack under vehicle. Arrow on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission.
- Secure transmission on transmission bracket 3282 with bolt -A-.
- Support transmission from below by lifting transmission bracket.





- Remove engine/transmission lower connecting bolts.
- Remove engine/transmission rearmost connecting bolts (arrow).





- Press transmission off engine, press torque converter -A- out of drive plate (direction of arrow) using screwdriver-Be.
- Press torque converter against ATF pump.
- Swing transmission carefully toward subframe.
- Carefully lower transmission (guide past subframe).
- When lowering guide power steering pressure line past transmission.
- Secure torque converter with wire to prevent it falling out.

Installing
Install in reverse order. When doing this note the following:

- Before installing ensure torque converter is seated correctly in transmission.

CAUTION! When the torque converter is incorrectly installed the torque converter drive or the ATF pump will be destroyed when the transmission is connected to the engine.





- Check whether dowel sleeves for centering engine and transmission are in cylinder block, install if necessary.
- Make sure intermediate plate is correctly seated on engine.
- Install all engine/transmission connecting bolts.





- Install 6 new nuts (arrow) for securing torque converter to drive plate using socket bit V/175.

Note:
^ The nuts must always be replaced
^ Turn crank 60° further in each case to tighten all the nuts

Install assembly mountings as follows:





- Place transmission bracket -A- between transmission and transmission mounting.
- Pull transmission carefully up to transmission mounting using support assembly spindles.

CAUTION! Before installing the transmission bracket/transmission mounting bolts, ensure that the bracket and mounting are absolutely parallel to one another. If not, the threads will be damaged. Press the transmission upward in the area of the final drive with transmission jack VAG 1383 A if necessary.





- Securely tighten bolts -1- and -2.

WARNING: Do not remove the support assembly 10-222A until the bolts on the left and right-hand assembly mountings have been tightened to the prescribed torque.





- Install pendulum support -4-.
- Install power steering line -2- to transmission (arrow -A-).
- Install axle shafts. Replace transmission side circlips on axle shaft when doing this.
- Install battery and battery carrier.
- Observe required measures before and after reconnecting battery.
- Check selector lever cable adjustment] adjust cable if necessary.
- Check ATF level and top off if necessary.
- Enter radio code.
pro multis Credits:Operation CHARM About Operation CHARM