With the 3.0L TDI Engine

Transmission

Short Description

The transmission is removed individually in a downward direction in this vehicle. The engine remains in the vehicle.

Special tools, testers and auxiliary items required

• Bracket (30-211A)

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

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Universal Support (V.A.G 1359/2)

• Socket (T40058)

• Depth Gauge (VAS 6082)

• Engine Bung Set (VAS 6122)

• Hose Clamps up to 40 mm Dia. (3093)

• Hose Clamps up to 25 mm Dia. (3094)

• Engine Support Basic Set (T40091)

• Engine Support Supplement Set (T40093)

• Hose Clip Pliers (V.A.G 1921)

• Step Ladder (VAS 5085)

• Tensioning Strap (T10038)

• Drip Tray for VAS 6100 (VAS 6208)

Removing

- On vehicles with an air suspension, activate the vehicle lift mode.

- Carefully remove the engine cover from the 4 ball studs one after the other - arrows -.






- Turn off the ignition and disconnect the battery ground cable.

- Loosen the nut - arrow - and remove the bracket - 1 - from the bulkhead, so that the engine does not bump into the bracket when tilted.






- Remove the noise insulation from under the engine and transmission.

- Remove the noise insulation bracket nuts - arrows - and bracket.






- Remove the rear section of the exhaust system.

- Remove the front and rear driveshafts.

- Remove the diesel particulate filter.

- Disconnect the connectors - 1, 2 and 3 - from the transmission.






- Install the crossmember (T40091/1) with the adapters (T40091/4) , (T40091/5) and the adapter (T40093/6) to the body. For this purpose, install the M8 x 30 bolts - A - next to the large opening - arrow - in the body.






- Install the spindle (T40091/6) with the square nut (T40091/7) in the adapter (T40093/6).

- Then, mount the spindle (T40091/6) and the thrust piece (T40091/8) on the automatic transmission housing.

- Remove the transfer case - B - with the transfer case support - C -.

- Support the engine.

• The special tools needed for removing the transfer case must now be removed.

- Support the engine with the engine support bridge from above, lower the transmission via the spindle (T40091/6) and remove the crossmember (T40091/1) with the adapters from beneath the transmission.

- Remove the heat shield - A - from the steering gear.






• Only disconnect the universal joint from the steering gear if the front wheels are in the straight ahead position.

• To maintain the position of the steering wheel and steering gear, secure the steering wheel with adhesive tape.

- Remove the universal joint bolt - B - and then remove the universal joint from the steering gear.

- Remove the catalytic converter.

- Remove the selector lever cable - 1 - from the selector shaft ball stud using the pry lever - rmv outside mirror (80-200) and remove the lock washer - 3 -.






A removed lock washer may not be reinstalled. Always replace the lock washer.

• Do not bend or kink the selector lever cable.

- Remove the catalytic converter bracket bolts - arrows - and bracket - 1 - from the transmission.






- Remove the bolts - arrows A and B - and remove the heat shield - 1 - (for the coolant lines) and the heat shield - 2 - (for the selector lever cable) from the transmission.






- Remove the vacuum hose - 1 - from the vacuum pipe - 2 - (leads to the brake booster).






- Place the drip tray for VAS6100 (VAS 6208) under the engine/transmission.

- Clamp off the coolant hoses on the left side of the transmission using the hose clamps up to 25 mm dia. (3094).






- Then, remove the hose clamps from the coolant pipes - A -, using for example the hose clip pliers (V.A.G 1921). Disconnect the coolant hoses from the coolant pipes.

- Clamp off the coolant hoses on the right side of the transmission using the hose clamps up to 40 mm dia. (3093) and disconnect the coolant hoses from coolant pipes - A -.






- Remove the breather hose - B - from the clip on the coolant pipe.






- Remove the bolts - arrows - and remove the coolant pipes - A - from the transmission

- Remove the bolts - 1 and 2 - and remove the transmission fluid pipes from the transmission. Collect the leaking fluid.






- Seal the pipes with a suitable plug from the engine bung set (VAS 6122) (protect against the penetration of dirt).

- Remove the transmission fluid pre-heater bolts - arrows - and pre-heater from the transmission.






- Disconnect the connector - 1 - from the change-over valve (N180) - 2 - and remove the pre-heater together with the coolant pipes from the transmission.






- Disconnect the connector - 1 - from the multifunction transmission range switch (F125) - 2 -.






- Remove the starter.

- Assemble the socket (T40058) as follows.






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the socket

- Counter hold the crankshaft using the socket (T40058) and an angled box end wrench in order to loosen the torque converter bolts at the drive plate.






• Rotate the crankshaft only in engine rotation direction - arrow -.

- Remove the cap - 1 -.






- Remove the 6 torque converter bolts - arrows - through the opening for the starter (rotate the crankshaft 1/3 rotation in engine rotation direction).

• Loosen and tighten the torque converter bolts - arrows - at drive plate - 2 - with a T55 TORX(R) socket (100 mm long). Do not allow the bolts to fall into the transmission housing.

- Remove the engine/transmission bolts at the top - 4 through 6 - and at the bottom - 8 through 10 -. The bolts - 3 and 7 - remain installed.






- Install the engine-/gearbox jack (V.A.G 1383 A) with the universal support (V.A.G 1359/2) under the transmission. Place a wooden block between the transmission fluid pan and the universal support.






• Secure the transmission to the universal support with the tensioning straps (T10038).

- Relieve the load on the engine and transmission at the top via the engine support bridge. Use the step ladder (VAS-5085) for this.

- Remove the remaining engine/transmission bolts.

- Pry the transmission off of the engine, and separate the torque converter from the drive plate.

• During removal, it must be ensured that the torque converter does not slip out of the transmission.

- Lower the transmission using the engine-/gearbox jack (V.A.G 1383 A).

- After the removal of the transmission, install the bracket (30-211 A) to secure the torque converter against falling out.






Installing

Installation is performed in the reverse order of removal while observing the following:

In the case of dirty transmission fluid or before installing a replacement transmission, clean the transmission fluid cooler and pipes. Refer to => [ Transmission Fluid Pipes and Cooler, Cleaning ] ATF Pipes and Cooler, Cleaning.

Use a wire brush to clean the threads of bolts that were installed using locking fluid. Install the bolts using liquid locking fluid (AMV 185 101 A1).

Use a thread tap to clean all threaded holes containing self-locking bolts to remove any locking fluid residue. Otherwise the bolts could shear the next time they are removed.

- Always replace self-locking nuts and bolts.

- Reconnect all electrical connections, lines and hoses that were disconnected during removal.

- Prior to installation of the transmission, ensure that the torque converter is properly installed in the transmission. Refer to => [ Torque Converter, Installing ] Torque Converter, Installing.

- Check the installation dimension - a -. Refer to => [ Installed Dimension ] Torque Converter, Installing.






Prior to installation of the transmission to the engine, ensure that there are alignment sleeves for centering the engine/transmission, if not install them.

- If a replacement transmission is installed, it must be positioned on the universal support (V.A.G 1359/2) as during removal. Secure the transmission using the tensioning straps (T10038).

- Align the transmission with respect to the engine and install it.

If the engine and transmission are connected with force when the converter is installed incorrectly, damage to the transmission and converter results.

- When securing the transmission to the engine, always make sure the converter is rotating freely and not jammed.

- Install and tighten the engine/transmission bolts - 3 through 10 -.






- Install 6 torque converter bolts - arrows - to the drive plate - 2 - (rotate the crankshaft 1/3 rotation in the engine rotation direction).






• Tightening specification: 85 Nm.

- Install the cap - 1 -.

- Install the starter.

- Install the pre-heater and bolts - arrows - to the transmission, install the coolant pipes to the transmission and connect them with the coolant hoses.






- Remove the plugs and install the pipes to the transmission until seated.






- Install the bolts - 1 and 2 -. Refer to => [ Transmission Fluid Pipe Overview ] Transmission Fluid Pipe Overview.

- Carefully install the selector lever cable - 1 - to the selector shaft ball stud. Do not bend the selector shaft when doing this. Otherwise shifting can no longer be adjusted precisely.






- Install the new lock washer - 3 -.

- Check the selector lever cable setting, and adjust if necessary. Refer to => [ Selector Lever Cable, Checking and Adjusting ] Adjustments.

- Install the heat shields and the catalytic converter bracket to the transmission.

- Install the catalytic converter.

- Install the steering column universal joint to the steering gear.

- Install the transfer case with the transfer case support.

- Install the diesel particulate filter.

- Install the front and rear driveshafts.

- Install the rear section of the exhaust system.

Check the transmission fluid level and fill if necessary. Refer to => [ Transmission Fluid Level, Checking and Filling ] ATF Level, Checking and Filling.

- Add coolant.






Transmission to Engine Bolt