Transmission, Removing

Transmission, Removing

Short Description

The transmission is remove downward by itself.

From above:

The battery, air filter housing and starter are removed. The coolant hoses are clamped off. Before removing the subframe, the engine and transmission must be supported.

From underneath:

The pendulum support and the left drive axle are removed. The subframe remains in the vehicle.

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Adjustment Plate (3282/42A)

• Adapter (10-222 A/18)

• Engine Support Adapter (10-222 A/3)

• Transmission Support (3282)

• Insert Tool 18 mm (T10179)

• Bracket (T10346)

• Multipoint Socket (T10035)

• Engine Support Feet (10-222 A/8)

• Hose Clamps up to 40 mm (3093) , if not available, use Hose Clamps up to 25 mm Dia. (3094)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Tensioning Strap (T10038)

• Socket and Extended Bit (T10107 A) or Hex Extension (V.A.G 1669)

• Bracket with Spindle and Hook (10-222 A/10)

• Bracket (T10346)

• Engine Support Device (3300 A)

Removing

- Lift the vehicle, all 4 lift points of the hoist must be at the same height.

- Remove the left front wheel.

- Move the selector lever into the "P" position.

• Do not lower the vehicle onto the floor after loosening the drive axle bolt.

- Apply the brake pedal in order to remove the left drive axle bolt - arrow -. (2nd technician required).






- Remove the air filter housing.

- Remove the battery, the battery tray bolts - arrows - and tray.






- Disconnect the connector - 1 - from the Mechatronic unit.






- Remove the starter - A -.

Remove the lower starter bolt first.

- Disconnect the ground strap from the bracket.

- Remove the selector lever cable from the transmission.






Use pliers to remove the lock washer. Do not use a sharp tool otherwise the rubber grommet on the cable may get damaged.

Always replace both lock washers - arrows -.

- Remove the cable from the transmission cable bracket. Do not bend the cable.

The cable can be removed later when the transmission is lowered. Pay attention to the cable while the transmission is being lowered.

Later, install the small lock washer only after having checked and adjusted the cable. Refer to => [ Selector Lever Cable, Checking ] Selector Lever Cable, Checking.

- Clamp off the coolant hoses to the oil cooler using either the hose clamps up to 40 mm (3093) or the hose clamps up to 25 mm dia. (3094) and remove the hoses.






- Remove the upper engine to transmission bolts.






These tools are suitable for this.

Special tools, testers and auxiliary items required

• Multipoint Socket (T10035)

• Socket, Multi Point Bit XZN 14 (T10061)

• Bits (T10099)

• Insert Tool 18 mm (T10179)

It is advisable to complete the work under the vehicle now. This prevents the weight of the engine from resting on the engine support bridge and therefore on the body for a long period of time.

- Remove the noise insulation and lower section of the left front wheel housing liner if necessary. Refer to the following:

- Remove the charge air hose between the charge air cooler and the charge air pipe.





- Remove the fan shroud - arrow -.






- Remove the wire bracket from the large transmission cover (2 M6 nuts).






Tightening specification: 10 Nm

- Disconnect the connector - 1 - from the oil level thermal sensor.






- Remove the exhaust system suspended mount bolts - arrows - from the subframe.






- Disconnect the exhaust system at the double clamp - arrows -.






- Either tie up the front exhaust pipe or lay it on the tunnel bridge.

- Remove the left drive axle.

- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.






- Remove the right drive axle from the transmission.

- Secure the drive axle to the strut using a tensioning strap (T10038).






Do not damage the surface of the dive axle.

- Remove the pendulum support. First, remove the bolt - 1 - then remove the bolts - 2 and 3 -.






- Remove the right transmission flange shaft bolt and shaft using the socket and extended bit (T10107 A).






The bolt has a 6 mm inner hex socket. It can also be removed and installed using the hex extension (V.A.G 1669).

- To remove and install the flange shaft, install 2 bolts into the flange and counter hold it using a pry bar.






- Remove the flange shaft and the pressure spring.

- Plug the opening for the flange shaft with a suitable plug.

- When installing, press the flange shaft against the transmission with a pry bar and install the bolt.

Tightening specification: 30 Nm

- Remove the filler pieces from both fender upper edges.

- Disconnect any hoses and wires in the area of the lifting eyes on the engine.






- Install the engine support bridge (10-222 A) on the upper longitudinal member.

Installing the engine support bridge on the fenders will damage them.

- Support the engine and the transmission using the engine support bridge (10-222 A) and bracket with spindle and hook (10-222 A/10). Do not lift up yet.

- Remove the transmission mount to transmission mount bracket bolts - 2 - and the transmission mount bracket - A - to transmission bolts - A -.






- Lower the engine/transmission using the spindle until it is possible to remove the bracket - A -.

Three turns maximum on each spindle is enough to remove the bracket - arrow -.

In many cases it is not necessary to lower the spindles when removing the transmission later.

Remove the bracket - arrow -.






- If necessary, remove the secondary air injection pump motor bracket and pump and lay it aside.

- Remove the remaining bolts except for one bolt between the engine and transmission.

It is advisable to leave a bolt that is easily accessible.

- Remove the right bolt for the heat shield - 1 - from the subframe.






- Install the bracket (T10346) to the subframe with a bolt - 2 -.

Bolt - 2 - = M6 x 20

- Attach the engine support device (3300 A) to the bracket (T10346).

- If possible, place the support device against the engine crankcase.

- Push the engine and transmission far enough forward until there is enough clearance to remove the transmission.

• Be careful not to bend or damage the connecting lines, hoses and radiator when moving the engine/transmission subassembly.

- Align the transmission support (3282) with the adjustment plate (3282/42A).

- Guide the engine-/gearbox jack (V.A.G 1383 A) under the transmission and support it. Do not lift up yet.

The transmission is disconnected from the engine in this position.

- Remove the last engine to transmission bolt.

- Separate the transmission from the engine while being careful of selector lever cable and lower the transmission.

Transport the transmission and secure it to the assembly stand. Refer to => [ Transmission, Transporting and Securing to the Assembly Stand ] Transmission, Transporting and Securing to the Assembly Stand.

Install the transmission. Refer to => [ Transmission, Installing ] Transmission, Installing.