Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Transmission Support (3282)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Tensioning Strap (T10038)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Adapter (VW 771/40)
• Hose Clamps up to 25 mm Dia. (3094)
• Pin (3282/29)
• Adjustment Plate (3282/33)
• Grease for Clutch Plate Splines (G 000 100)
• M10 x 20 Bolt
Perform the following:
- Turn off the ignition and disconnect the battery ground cable.
- Remove the engine cover.
- Remove the air filter housing.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 -.
- Remove the shift cable - 2 - from the transmission shift lever pin - arrow -.
• To avoid damage to the selector cable, the cable retainer must be disconnected from the relay lever before removal.
- Pull the locking mechanism all the way forward in the - direction of arrow 1 - and then unlock it to the left in the - direction of arrow 2 -.
- Remove the relay lever with the cable retainer.
- Remove the cable bracket bolts and nut - arrows - from the transmission, and move it to the side and secure it.
Vehicles with a line between the clutch master and slave cylinders:
- Clamp off the supply hose from the brake fluid reservoir to the clutch master cylinder using a hose clamp up to 25 mm dia. (3094).
Vehicles with a hose/line assembly between the clutch master and slave cylinders:
- Clamp off the hose in the hose/line assembly - A - from the clutch master cylinder to the clutch slave cylinder using a hose clamp up to 25 mm dia. (3094).
Continuation for all:
- Pull the clip - arrow - for the hose/line assembly or line out to the stop.
- Remove the hose/line assembly or line from the breather assembly/clutch slave cylinder and seal it off.
Do not press the clutch pedal anymore.
- Remove the ground strap - 1 - from the top starter bolt.
- Disconnect the connector - arrow 2 - from the backup lamp switch (F4).
- Disconnect the connector and the wire from the starter.
- Remove the upper engine/transmission stud bolts - arrows -.
- Remove the upper bolt from the starter.
- Remove the plenum chamber cover.
- Remove the lock carrier trim.
- Disconnect any hoses and wires in the area of the lifting eyes on the engine.
- Remove the left and right side lock carrier bracket bolts - arrows -.
- Remove the lower mounts from the adapters (10-222 A/28) and replace them with the adapters (10-222 A/28-1).
- Mount the adapters (10-222 A/28) with adapters (10-222 A/28-1) onto the lock carrier and secure them to the threaded holes for the lock carrier bracket with the bolts - arrows -.
• Use the bolts from the adapters (10-222 A/28-1) when securing the adapters (10-222 A/28) and not the bolts for the lock carrier brackets.
• Bolt - arrows - tightening specification: 8 Nm.
A second technician will be needed for installing the engine support bridge (10-222 A) to the vehicle in order to prevent the engine support bridge from tipping over.
Install the engine support bridge as follows:
1. Adapter (10-222 A/31-2)
2. Moveable joint (T40091/3)
3. Adapter (10-222 A/31-1)
4. Moveable joint (T40093/4)
5. Square pipe (T40091/1)
6. Adapter (10-222 A /28) with adapter (10-222 A/28-1)
- Slide the moveable joints (T40091/3) (- 2 -) onto the square pipe of the engine support bridge (10-222 A).
• The bolts for the moveable joints (T40091/3) (- 2 -) on the square pipe face the front.
- Mount the engine support bridge (10-222 A) on the strut towers and have a second technician hold it to keep it from falling over.
- Push the left and right square pipes (T40091/1) (- 5 -) from the front, through the adapters (10-222 A/28) (- 6 -) and install the moveable joints (T40093/4) (- 4 -) on each pipe.
- Slide the rail with holes (T40091/2) (- 8 -) with the mount (T40093/5) (- 7 -) in the moveable joint (T40093/4) (- 4 -).
1. Adapter (10-222 A/31-2)
2. Moveable joint (T40091/3)
3. Adapter (10-222 A/31-1)
4. Moveable joint (T40093/4)
5. Square pipe (T40091/1)
6. Adapter (10-222 A/28) with adapter (10-222 A/28-1)
7. Mount (T40093/5)
8. Rail with holes (T40091/2)
9. Spindle (10-222 A/11)
- Install the locking pins into the rail with holes (T40091/2) (- 8 -) and secure them.
- Tighten the threaded connections on the engine support bridge hand tight. Adjust the height of the engine support bridge parallel over the adapters (10-222 A/28).
- Tension the engine/transmission subassembly using the spindles (10-222 A/11) (- 9 -) slightly, but do not lift it.
- Loosen the left and right front wheel bolts.
- Raise the vehicle and remove the front wheels.
- Remove the noise insulation.
- Remove the left and right front wheel housing liner..
- Remove the bracket from the starter.
- Remove the lower bolt from the starter and then remove the starter.
- Separate the exhaust system at the clamping sleeve and remove the suspended mount bolts - arrows - from the subframe.
- Tie up the front exhaust pipe with catalytic converter.
• Do not bend the coupling element in the front exhaust pipe more than 10° or it will be damaged.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Remove the pendulum support bolts - 11 - from the transmission.
- Secure the subframe.
• If the subframe is not secured, a wheel alignment must be performed later.
- Remove the subframe with steering gear.
- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove the left and right drive axle from the transmission flange shafts.
- Tie the right drive axle up as high as possible.
- Move the left drive axle to the rear and secure it. Be careful not to damage the surface protection.
- Remove the small flywheel cover plate - A - - arrows -, if equipped.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
- Lower the engine/transmission subassembly approximately 40 mm - a - using the spindles on the engine support bridge (10-222 A).
• When moving the engine/transmission assembly, pay attention to the wires and hoses.
- Remove the transmission mount bracket - 1 - to transmission bolts - arrows -.
- Remove the clip - arrow 1 - and then remove the relay lever and cable retainer - arrow 2 -.
- Remove the transmission shift lever from the gear shift shaft.
- Remove the lower engine/transmission bolts - 2 -.
• Remove the engine/transmission bolts - 1 and 3 - later in the procedure.
To remove the transmission, the adjustment plate (3282/33) must be installed on the transmission support (3282).
- Install the transmission support (3282) on the engine-/gearbox jack (V.A.G 1383 A).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the support elements - A - as illustrated on the adjustment plate.
- Install the pin (3282/29) in place on the adjustment plate - C -.
- Position the engine-/gearbox jack (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the adjustment plate points in the direction of travel.
- Align the adjustment plate so that it is parallel to the transmission.
- Remove the transmission/engine bolt - C -.
- Install the adapter (VW 771/40) inside the threaded hole in the transmission housing as illustrated.
- Secure the transmission to the transmission support (3282) with a M10 x 20 bolt - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
- Install the pin (3282/29) into the hole in the transmission for the pendulum support bolt.
- Remove the last engine/transmission bolt - arrow - under the right flange shaft.
- Separate the transmission from the engine (alignment sleeves).
- Move the transmission in the area of the differential using the spindles on the transmission support (3282) into an angled position.
• The differential, near the transmission, must face upward.
The right flange shaft - 1 - must be guided over the bolt flange - 2 - on the cylinder block.
- When doing this, be careful of the longitudinal member - arrows -.
- Then carefully lower the transmission.
• Pay attention to the wires and hoses when lowering the transmission.
Transmission, transporting, refer to => [ Transmission, Transporting ] Procedures.