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 steering gear wiring harness is disconnected and freed up. This way it can be lowered together with the subframe and the steering gear. The engine and transmission are supported before the transmission mount bracket is removed.
From underneath:
The subframe, with the pendulum support, the steering gear and both control arms are removed together.
Both drive axles are disconnected from the transmission and remain inside the wheel bearing housings. Occasionally they will be moved to the side, but they still remain on the vehicle.
To remove the subframe. If done correctly, the subframe can be removed and installed without the customer experiencing increased tire wear later. It is recommended to read this information prior to removing the transmission. This way, the subframe can be secured and removed correctly.
Locating pins (T10096) will l be needed.
If the subframe is not secured using the locating pins (T10096) , then later a wheel alignment will be necessary.
In this case, a wheel alignment is unnecessary. It would be a lot of work and an unnecessary charge!
Special tools, testers and auxiliary items required
• Transmission Support (3282)
• Adjustment Plate (3282/42 A)
• Pin (3282/29)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Engine Support Bridge (10-222 A)
• Hose Clamps up to 25 mm dia. (3094)
• Hose Clamps up to 40 mm (3093)
• Tensioning Strap (T10038)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Engine Bung Set (VAS 6122)
- Move the selector lever into the "P" position.
- 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 selector lever cable lock washers - arrows -.
• Use pliers to remove the lock washers. Do not use a sharp edged tool. Otherwise the selector lever cable could get damaged.
• Remove the cable bracket - 2 - from the transmission, if necessary. Remove the bolts - 1 - and the lock washer - 3 -.
• Replace the bolts - 1 - and lock washers.
• Bolt - 1 - tightening specification, see item 7 in => [ Selector Mechanism ] Selector Mechanism.
Remove the cable from the transmission cable bracket. Do not bend the cable.
Later during installation, only install new lock washers after you have checked and adjusted the cable. Refer to => [ Selector Lever Cable, Checking ] Testing and Inspection.
- Place a lint free cloth under transmission oil cooler on top of transmission to absorb any leaking coolant.
• When the engine is warm, the cooling system is under pressure.
• Cover the cap on the expansion tank with a cloth and open it carefully before removing the coolant hoses.
- Clamp off the coolant hoses using the hose clamps up to 25 mm dia. (3093) and remove the hoses from the transmission oil cooler.
- Seal the transmission oil cooler connections with plugs from the engine bung set (VAS 6122).
- Remove the starter - A -.
Remove the lower bolt first.
Risk of destroying the DSG transmission Mechatronic (J743) with static electricity.
• Do not touch the contacts in the Direct Shift Gearbox (DSG) Mechatronic unit connector with hands.
- To discharge any static electricity, touch a grounded object with your hand (without wearing a glove). Refer to => [ Electrical Components ] Electrical Components.
- Turn the Mechatronic unit connector - 1 - counterclockwise and then disconnect it.
- Remove all the upper engine/transmission bolts
These tools are suitable for this.
• Multipoint Socket (T10035)
• Socket, Multipoint Bit XZN 14 (T10061)
• Bits (T10099)
• Insert Tool 18 mm (T10179)
One bolt - arrow - is located inside the hole for the starter. Use the socket, multipoint Bit XZN 14 (T10061) to remove this bolt.
- Disconnect any hoses and wires in the area of the lifting eyes on the engine.
- Remove the plenum chamber cover.
- Remove the lock carrier trim.
- Remove the left and right lock carrier bracket bolts - arrows -.
- Remove the lower mount from the adapters (10-222 A/28) and replace them with adapters (10-222 A/28-1).
- Install the adapters (10-222 A/28) with the adapters (10-222 A/28-1) on the left and right lock carriers and secure them in the threaded holes form the lock carrier brackets - arrows -.
• Use the bolts in the adapters (10-222 A/28-1) for 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 when 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 joint (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 (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 place the moveable joints (T40093/4) (- 4 -) on each side.
- Slide the rail with holes (T40091/2) (- 8 -) with the mounts (T40093/5) (- 7 -) in the moveable joints (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. Slotted rail (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) (- 6 -).
- 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 liners.
- Remove the electric wires, the bracket nuts - arrows - (two M6 nuts) and bracket from the front transmission cover.
- Route the wires near the transmission cover upward and secure them.
- Separate the exhaust system at the clamping sleeve and remove the suspended mount bolts - arrows - from the subframe.
- Tie up the front exhaust pipe.
• Do not bend the coupling element in the front exhaust pipe more than 10° or it will be damaged.
- Remove the pendulum support bolts - 11 - from the transmission.
- Secure the subframe.
• If the subframe is not secured, a vehicle alignment must be performed later.
- Remove the subframe with steering gear.
- Remove the right drive axle heat shield bolts - arrows - and heat shield.
- Remove the drive axles from the transmission.
- Tie the right drive axle as high up as possible using the tensioning straps (T10038).
- Move the left drive axle to the rear and secure it. Be careful not to damage the surface protection.
- There may be a small cover plate - A - between the engine and transmission above the right flange shaft. Remove the cover plate, if equipped.
- Remove the transmission mount to transmission mount bracket bolts - 2 - and the transmission mount bracket to transmission bolts - 1 -.
- Then, lower the engine/transmission slightly using the spindles on the engine support bridge (10-222 A) so the bracket can be removed.
- Remove the transmission mount bracket - arrow -.
To remove the transmission, the transmission support (3282) , must be equipped with the adjustment plate (3282/42 A) and installed 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 (3282/42 A).
- Install the support elements on the adjustment plate (3282/42 A) as illustrated.
- Place the engine-/gearbox jack (V.A.G 1383 A) under the vehicle.
• The arrow symbol on the adjustment plate (3282/42 A) points in the direction of travel.
- Align the transmission support (3282) so that it is parallel to the transmission.
- Screw the pins (3282/29) into the transmission.
- Secure both support elements to the transmission as illustrated.
• Deviating from the illustration of the adjustment plate, the front transmission support is illustrated mounted to the transmission - arrow -.
• A All Wheel Drive (AWD) DSG is shown in the illustration. The mounting elements for a Front Wheel Drive (FWD) DSG are identical.
- Lift the engine-/gearbox jack (V.A.G 1383 A) to support the transmission from underneath.
The transmission is separated from the engine in this position.
- Remove all remaining engine/transmission bolts.
- Remove the transmission from the engine while being careful of selector lever cable and lower the transmission.
• Pay attention to the lines when lowering 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.