With the 3.6L 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)

• Depth Gauge (VAS 6082)

• Engine Bung Set (VAS 6122)

• Tensioning Strap (T10038)

• Drip Tray for VAS 6100 (VAS 6208)

• Engine Support Basic Set (T40091)

• Engine Support Supplement Set (T40093)

• Counterhold Tool Touareg V10 (T10172)

• Step Ladder (VAS 5085)

Removing

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

- Remove the engine cover.

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

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

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






- Remove the front and rear driveshafts.

- Disconnect the connectors - 1 through 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. A bolt on the right must be removed from the exhaust system.






- 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.

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






- Remove the bolts - arrows - and disconnect the coolant pipes - A - from the transmission.

- Remove the catalytic converter bracket bolt - arrow -.






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

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






- Depending on the equipment, the front transmission fluid pipes can be secured to the catalytic converter bracket - arrows -. Remove the bolts and remove the bracket from the transmission.






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

- Remove the change-over valve (N180) - 2 - from the bracket. The connector - 1 - is not disconnected from the valve.






- Remove the transmission fluid pre-heater bolts - arrows - and pre-heater from the transmission. The coolant pipes remain on the pre-heater.






- Unclip the wiring harness from the transmission.

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






- Remove the starter.

- Remove the cap.






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

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

- Rotate the crankshaft using the counter hold tool Touareg V10 (T10172) to loosen the torque converter bolts at the drive plate.






- Remove all engine/transmission bolts except for 2 easily accessible bolts.

- 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 all remaining engine/transmission bolts.

- Pry the transmission from the engine, and separate the torque converter off of 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, use 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 installing the transmission to the engine, always make sure the converter is rotating freely and not jammed.

- Install the engine/transmission bolts.






- Install and tighten the 3 torque converter bolts - arrow - to the drive plate. Rotate the crankshaft 1/3 turn further in engine rotation direction.






- Install the cap.

- Install the starter.

- Install the pre-heater and bolts - arrows - to the transmission.






- Remove the plug and insert the pipes to the transmission until seated.






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

- Depending on the equipment, the front transmission fluid pipes may be secured to the catalytic converter bracket - arrows -.






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

- Carefully press the selector lever cable - 1 - onto the selector shaft ball stud and install a new lock washer - 3 -. Do not bend the selector shaft when doing this. Otherwise shifting can no longer be adjusted precisely.






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

- Install the transfer case with the transfer case support.

- Install the front and rear driveshafts.

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

- Further installation is performed in the reverse sequence.






Transmission to Engine Bolts