Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Adapter (10-222 A /3)
• Adapter (10-222 A /8)
• Adapter (10-222 A /18)
• Transmission Support (3282)
• Transmission support elements (determine when mounting the adjustment plate on the transmission support )
• Adjusting Plate (3282/62)
• Transmission Support Jig (3336) for transporting the transmission
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Torque Wrench 40-200 Nm (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• 2 x Bracket (T10346)
• Bracket (T10346/1)
• Engine Support Device (3300 A)
• Adapter for VW771 Slide Hammer (VW 771/40)
• Hose Clamps up to 25 mm Dia. (3094)
• Pin (3282/29)
• Grease for clutch disc shaft splines (G 000 100)
• For the correct grease, refer to the Parts Catalog.
• M6 x 80 collar bolt
• M10 x 20 bolt
• M12 x 30 bolt
• M6 x 20 collar bolt
• or
• M8 x 20 collar bolt
The (10-222 A) and the (10 - 222 A /8) will be mounted on the longitudinal members later in the procedure.
• To protect the edges of the fender, cover both (10 - 222 A /8) with cloth tape - arrow -. Refer to the Parts Catalog (ETKA chemical materials).
- Attach (T10346) to (T10346/1) as illustrated.
A = M12 x 30 bolt with washers and an M12 nut
These brackets will be used later in the procedure to mount the (3300 A).
The brackets are attached to the subframe, in the center threaded hole for the noise insulation screw.
The noise insulation is attached to the subframe with M8 bolts.
- The (T10346/1) is needed for this.
The hole - arrow - inside the bracket (T10346/1) requires an M8 bolt.
- Remove the manual transmission together with the bevel box.
- See if a coded radio is installed. If so, obtain the anti-theft code.
- Turn off the ignition and disconnect the battery Ground (GND) cable.
Later in the procedure, the (10-222 A) is connected to engine lifting eyes.
- Remove the engine cover if it is blocking the lifting eyes.
- Remove the complete air filter housing if it is near the battery.
- Remove the battery and the battery tray.
- Remove the lines - A - from the mount - B -.
- Remove the shift cable lock washer - 1 - from the transmission shift lever - 2 - and remove the cable from the pin - arrow -.
- Remove the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
- Pull the securing mechanism all the way forward in direction of - arrow 1 - and then unlock to the left in direction of - arrow 2 -.
- Push the relay lever forward (direction of - arrow 3 -).
- Remove the relay lever with the cable retainer.
- Remove the cable bracket from the transmission - arrows -, move it to the side and tie it up.
Vehicles with a pipe between the clutch master and slave cylinders
- Clamp off supply hose to master cylinder with a (3094).
Vehicles with a hose/line assembly between the clutch master and slave cylinders
- Clamp the hose for the hose/line assembly - A - to the clutch slave cylinder with (3094).
Continuation for All
- Pull the clamp - arrow - for the hose/line assembly or pipe out to the stop.
- Remove the hose/line assembly or pipe from the bleeder/slave cylinder and seal it off.
Do not press the clutch pedal anymore.
- Disconnect the connector and the wire from the starter.
- Remove the upper engine/transmission connecting bolts - arrows -.
The bolt heads may be different than those in the illustration.
- Remove the upper bolt from the starter.
- Attach the (T10346) to the rear hole of the 3 holes on the battery tray.
- Use a M6 x 80 collar bolt or a one of the bolts for the battery tray.
- Disconnect any hoses and cables in the area of the (10-222 A) lifting eyes on the engine.
- Position the (10-222 A) in front of the engine hood support.
- Use:
• Adapter (10-222 A /3)
• Adapter (10-222 A /8)
• Adapter (10-222 A /18)
• Engine support feet (10-222 A /8)
• On the upper longitudinal members
• Directly in front of the ridge (- arrow 1 -),
• Locate next to the bolt (- arrow 2 -).
- Attach the (T10346) to the engine support bridge.
- Hook the spindles into the left lifting eye on the engine.
- Tension the engine/transmission assembly and engine support bridge via the spindles.
The front drive axle must be removed later in the procedure.
- With the vehicle still standing on its wheels, loosen the left front collar bolt - arrow - a maximum of 90°, otherwise the wheel bearing will get damaged.
- Lift the vehicle.
- Remove the noise insulation.
- Remove the lower section of the left and right front wheel housing liners.
- Remove the nut - 1 - and remove the bracket with the electric wires from the lower starter bolt.
- Remove the starter.
- Disconnect the connector - 2 - from the back-up lamp switch (F4).
- Remove the left charge air hose - arrow 1 - and - arrow 2 -.
- Remove the right charge air hose from the charge air cooler.
- Remove the air shroud - arrow - and coolant fans.
- Remove the pendulum support.
- Remove the connector - 1 - from the oil level thermal sensor (G266).
- Remove the left front vehicle level sensor (G78) from the transverse links, if equipped.
- Remove the drive axle heat shield, if equipped, from the bevel box (- arrows -).
- Remove the front drive axles.
Vehicles with a Vacuum Diaphragm from 11/09 - arrow 1 -
From 11/09, a brace - arrow 2 - is installed under the vacuum diaphragm - arrow 1 - at the top of the transmission support (gradual introduction).
- Loosen the transmission support bolts - A - to the engine.
- Remove the transmission support bolts - B - from the bevel box.
Continuation for All
- Mark the position of the driveshaft with the flexible disk with respect to the bevel gear flange with paint.
- Remove the driveshaft from the bevel box - arrows -.
- Push the front driveshaft all the way back.
- Remove the Ground (GND) cable from the subframe mount.
- Remove the bolts - arrows - from the left subframe mount.
- Lower the transmission using the spindles attached to the engine.
- a - = approximately 60 mm
• When moving the engine/transmission assembly, be aware of the coolant hoses between the engine and heater core; do not strain.
- Remove the bracket from the transmission - arrows -.
- Remove the relay lever and cable retainer.
- Remove the shift lever from the shift shaft.
- Remove the engine/transmission connecting bolt - arrow - next to the bevel gear - A -.
- Loosen the engine/transmission connecting bolts - 2 and 3 - and leave them in hand-tight.
- Tighten the (T10346/1) and (T10346) with the bolt - 1 - to the bottom of the subframe.
- Use the center threaded hole meant for attaching the noise insulation cover.
- 1 - = M6 x 20 collar bolt or M8 x 20 collar bolt.
- Attach the (3300 A) to the brackets bracket.
- Place a cloth between the (3300 A) and the oil pan.
- Push the engine forward using the spindles on the (3300 A). Note the following points:
• The Air Conditioning (A/C) compressor - 2 - must not touch the refrigerant line - 1 - - arrow -.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
To remove the transmission the "02Q AWD", the (3282) must be equipped the (3282/62).
- Install the (3282) in the (V.A.G 1383 A).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the support elements - A - as illustrated on the adjustment plate.
- Install the (3282/29) instead of the mount - C -.
• Arm - A - is shorter than arm - B - due to the position of the transmission support.
• The mount must be attached to arm - A - (the shorter arm) with the (3282/29).
• This makes it easier to guide the shorter arm past the engine support - arrow - later.
- Position the (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the adjusting plate points in direction of travel.
- Align the adjustment plate so that it is parallel to the transmission.
- Install the pin (3282/29) into the hole in the transmission for the pendulum support bolt.
- Secure the adapter (VW 771/40) inside the threaded hole in the transmission housing as illustrated.
- Secure transmission on (3282) using bolt (M10 x 20) - A -.
The needle bearing drift - B - must be flush with the guide on the (3282) - arrow -.
- Remove the last engine/transmission connecting bolt - 3 -.
- Separate the transmission from the engine toward the front of the vehicle.
- Guide the bevel box around the cover plate - A - and, if necessary, around the transmission support - B -.
• Be careful not to damage the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid valve (N18) - arrow - and surrounding components.
- Be careful of the longitudinal member - arrow 1 - and of the subframe - arrow 2 -.
- Lower the transmission carefully. Be careful of the subframe and the (3300 A) - arrows - when doing this.
• Pay attention to the lines when lowering the transmission.