Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Adjustment plate (3282/39)
• Engine/transmission jack (V.A.G 1383A)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Transmission support jig (3336)
• Grease (G 000 450 02)
• Grease for clutch disc splines (G 000 100)
- First check whether a coded radio is installed. In this case, find out anti-theft coding.
- Disconnect battery Ground (GND) cable with ignition switched off.
- If engine mounting eyes for Engine Support Bridge (10 - 222 A) are covered by the cover or air filter, it must be removed now.
- Remove entire air filter housing, if it is located in the vicinity of the battery.
- Remove battery
- Remove lock washer - arrow 1 - for shift cable from transmission shift lever - A -.
- Remove shift cable from pins
Metal relay lever
- Remove lock washer - arrow 2 - for selector cable from relay lever - B -.
- Remove selector cable from pins
- Pull off locking washer - arrow 3 - from relay lever - B - and remove relay lever.
Plastic Relay Lever
- Disconnect cable retainer from selector cable --> [ Disconnect cable retainer from selector cable. ] Selector Mechanism
- Press tab - arrow 1 - down as far as stop and remove relay lever together with the cable retainer.
Continued for all
- Remove transmission shift lever - A - by removing the nut - arrow 4 - (previous illustration).
- Remove cable mounting bracket from transmission - arrows -.
- Then tie shift cable and selector cable up.
- Remove bracket - B - from transmission and pull it off from hose/line assembly - A -.
- Then remove transmission supports - arrows A -.
- Remove slave cylinder - arrow B - and lay aside, secure with wire, do not open wiring system.
CAUTION!
Clutch pedal must no longer be operated.
- Remove ground (GND) cable at upper engine/transmission connecting bolt.
- Disconnect connector - arrow 1 - from Back-Up Light Switch (F4).
- Then remove connector - arrow 2 - and wire - arrow 3 - from starter.
- Then remove upper bolt on starter.
- Remove upper engine/transmission bolts.
- Disconnect any hoses and cables in the area of the engine support bridge (10 - 222 A) lifting eyes on the engine.
- Position Engine Support Bridge (10 - 222 A) with Engine Support Feet (10 - 222 A /8), Adapter (10 - 222 A /3) and Adapter (10 - 222 A /16) in front of hood gas shocks.
- Hook in bracket with spindle and hook (10 - 222 A /10) at front right of the engine.
- Now hook additional hooks (10 - 222 A /2) in at left rear of the engine - arrow -.
- Then attach Additional Hooks (10 - 222 A /2) to Adapter (10 - 222 A /16).
- Pretension engine/transmission assembly on the spindles.
- Raise vehicle.
- Remove noise insulation
- Remove lower part of left front wheel housing liner
- Then remove all lines from transmission.
- If equipped, remove shield for driveshaft from engine - arrows -.
- Separate exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe
- Disconnect drive axles from flange shafts and tie up as far as possible, do not damage surface protective coating.
- Remove pendulum supports - arrows A -, - B - and - C -.
- Remove bolts - arrows B - of left assembly mounting from transmission mount.
- Bring engine/transmission assembly into angled position by lowering it over the engine support bridge (10 - 222 A) spindles.
• Install threaded spindle of the adapter (10 - 222 A /16) downward, via the wing nut, up to the maximum where the thread is flush - arrow -.
• Pay attention to all lines when lowering transmission.
• The bolts - arrows - for the transmission console - A - must be accessible.
- Remove transmission console - A - - arrows -.
- If installed, remove small cover plate - A - for flywheel behind right flange shaft - arrow -.
- Remove exhaust system brace - 1 - from transmission - arrow -.
- Remove starter
To remove the transmission "0A4", the transmission support (3282) must be equipped with the adjustment plate (3282/39).
- Place transmission support (3282) in Engine And Transmission Holder (V.A.G 1383A).
- Align arms of transmission support according to holes in adjustment plate.
- Install support elements - A - and - C - onto adjustment plate as shown.
- Place Engine And Transmission Holder under vehicle, with arrow symbol - B - on adjustment plate pointing to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety supports on transmission.
- Then install pin (3282/39) into hole for mounting bolt of pendulum support on transmission.
- Remove lower engine/transmission securing bolts.
- Press transmission off from alignment sleeves and carefully pivot it toward subframe.
- Rotate transmission downward in area of differential.
- Push engine forward slightly (2nd technician).
- Carefully lower transmission while guiding right flange shaft - A - into flywheel/intermediate plate area as shown.
- Use spindles of transmission support (3282) to adjust position of transmission while lowering.
• Pay attention to all lines when lowering transmission.
Transmission, Transporting
- Secure transmission support jig (3336) to clutch housing.
- Adjust support arm on sliding piece with locking pin - arrow -.
Number of visible holes = 5.
- Lift transmission using workshop crane and transmission support jig (3336).
- Set down transmission, e.g. in a transport container.