Transmission, Removing and Installing

Transmission, removing and installing, 09G, 6 Spd. A/T

Special tools, testers and auxiliary items required:

- Engine support bridge 10-222 A
- Adapter 10-222 A/8
- Shackle 10-222 A/12
- Hose clamps up to 25 mm dia. 3094
- Transmission support 3282
- Adjustment plate 3282/36

Special tools, testers and auxiliary items required:

- Torque wrench V.A.G 1331
- Torque wrench V.A.G 1332
- Engine and transmission jack V.A.G 1383 A
- Socket V/175

Removing

Note: Replace all cable ties which are opened or cut open when removing the transmission in the same position during installation.

- 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 removing reservoir.
- Tie up reservoir on lock carrier.
- Remove battery and battery carrier

Note: Observe the required measures before disconnecting the battery.

- Disconnect intake hose - 1 - and connector - 2 - from mass air flow sensor.
- Disconnect secondary air injection pump hose - 3 - from 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.

- Disconnect connector - 5 - from multi-function TR 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 mounted to the transmission, are damaged/destroyed during removal or for any other reason, replace the respective wiring harness (14-pin or 8-pin connector).

- Clamp ATF cooler hoses with hose clamps 3094 and disconnect from ATF cooler.
- Seal off ATF cooler with clean plugs.
- Remove Ground strap from engine/transmission upper connection bolt.
- Remove upper screws that connect engine to transmission.
- Mount engine support bridge 10-222 A with adapters 10-222 A/8.

Note: Do not set the adapters 10-222 A/8 on the securing bolts for the fender.

- Remove any hoses or wiring still located in vicinity of engine lifting eyes for engine support bridge 10-222 A.
- Secure left side spindle (transmission side) to engine lifting eye using shackle 10-222 A/12 if necessary.
- Pretension engine assembly by means of spindles.
- Remove both front wheels.

- Remove sound insulation - arrows -.
- Remove left side sound insulation.

- Remove sound insulation retainer - 1 -.
- Remove power steering line - 2 - on transmission - arrows A -.
- Remove left side axle shaft - 3 - complete
- Unbolt pendulum support - 4 - - arrows B -

- 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).
- Only disconnect the right side axle shaft 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 flanged shaft in the transmission; the axle shaft is inserted directly into the transmission.
- Only the wedge tool T10161 may 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 cover - A -.

- Remove nuts - arrow - from torque converter (Qty. 6) using socket V/175. Turn crankshaft 60° further to access next nut.

CAUTION: 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.

CAUTION: Do not bend the flexible element of the exhaust system more than 10° - otherwise it will be damaged.

- Remove transmission bracket - A - (remove bolts - 1 - and - 2 - ).
- Carefully tilt engine with transmission by lowering left side spindle (transmission side) on engine support bridge 10-222 A approximately 50 mm.
- The transmission support 3282 is set up with the adjusting plate 3282/36 for removing the 6 speed automatic transmission 09G.
- 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 3282/36 points to front of vehicle.
- Align adjustment plate 3282/36 parallel to transmission.
- Secure transmission on transmission support 3282 with bolt - A -.
- Support transmission from below by lifting transmission bracket.
- Remove engine/transmission lower connecting bolts.

- Remove engine/transmission rearmost connecting bolt - arrow -.

- Press transmission off engine and press torque converter - A - out of drive plate in - direction of arrow - using a screwdriver - B -.
- 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 from falling out.

Installing
Installation is performed in the reverse sequence of removal. In the process, note the following:
- Before installing transmission 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 - A - for centering engine/transmission are in cylinder block, install if necessary.
- Make sure intermediate plate is correctly seated on engine.
- Install all engine/transmission connecting bolts (items - 1 - to - 8 -. Tightening torques.

- Install 6 new nuts - arrow - for securing torque converter to drive plate using socket V/175. Tightening torques.

Note:
- Always replace the nuts.
- To install each nut turn the crankshaft 60° further.

- Install the 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 or the threads will be damaged. Press the transmission upward in the area of the final drive with engine/transmission jack V.A.G1383A if necessary.

- Securely tighten bolts - 1 - and - 2 -. Tightening torques.

CAUTION: Do not remove the engine support bridge 10-222 A until the bolts on the left and right side assembly mountings have been tightened to the specified torque.

- Install pendulum support - 4 -. Tightening torques.
- Install power steering line - 2 - to transmission - arrows A -
- Install axle shafts. Replace transmission side circlips on axle shaft when installing.
- Install battery carrier and battery
- Observe measures after having connected battery
- Check selector lever cable adjustment, adjust cable if necessary Selector lever cable, checking and adjusting.
- Check ATF level and top up ATF level, checking and topping up.
- Enter radio code

Tightening torques

Transmission to engine
- Replace bolts.

*Double stud with M8 threaded stud
*This double stud additionally secures starter to transmission
A: Dowelsleeves (for centering)
Bolts (items 7 and 8) also have a retainer

Transmission bracket - A - to transmission
- Replace bolts.

Pendulum support to transmission and assembly carrier
- Replace bolts.

Note: Install engine/transmission mounting without tension.

Torque converter nuts - arrow -. Qty. 6
- Replace torque converter nuts..

All other bolted connections:

- Ball joint to control arm bolts - arrows - and coupling rod - A - to control arm.