Transmission, Removing, Vehicles With 3.0L TDI BITURBO Engine

Special tools and workshop equipment required 

• Pry lever :80-200 
• Engine and Gearbox Jack :VAS6931 
• Crankshaft Turning Tool :T40257 
• Wrench - 21mm :T40263 
• Adapter :T40314 
• Crankshaft Socket :T40058 
• Gearbox Support :T40173 
• M8 x 20 bolt

Preparing the Gearbox Support :T40173  :

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-- The bracket attached to -1- must be removed.

-- The bracket -2- must be turned so that the longer side faces up as illustrated.

Removing 

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-- Position the front wheels so they are straight.

-- Disconnect the battery Ground (GND) cable -2-. Refer to BATTERY .

-- Remove the engine cover -arrows-.

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-- Remove the plenum chamber bulkhead. Refer to BULKHEAD .

-- Remove the pre-catalytic converter. Refer to EXHAUST PIPES/MUFFLERS [For engine(s) CYNB] or EXHAUST PIPES/MUFFLERS [For engine(s) CTGE, CEUC] or EXHAUST PIPES/MUFFLERS [For engine(s) CREC, CREH] .

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-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING [For engine(s) CYNB] or COOLANT, DRAINING AND FILLING [For engine(s) CTGE, CEUC] or COOLANT, DRAINING AND FILLING [For engine(s) CPNB] or COOLANT, DRAINING AND FILLING [For engine(s) CREC, CREH] .

-- Remove the front wheels. Refer to WHEELS AND TIRES .

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-- Remove left and right drive axle cover -1- in the wheel housing. Refer to NOISE INSULATION .

-- Remove the driveshaft. .

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-- Remove the ATF cooler. Refer to AUTOMATIC TRANSMISSION FLUID (ATF) COOLER, REMOVING AND INSTALLING .

-- Loosen hose clamps -2, and 3- and remove the coolant hose -1, and 4- from the heater core.

-- Disconnect electrical connectors -1 through 4- and move the wiring harness to the side.

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-- Remove the bolts -arrows- and then remove the air guide pipe -1-.

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-- Disconnect the connector -2-.

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-- Disconnect the connector -2-.

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-- Remove the bolt -3-, and remove the bracket with Exhaust Gas Temperature Sensor 3 -G495- and Differential Pressure Sensor -G505-.

-- Remove the left and right bolt -1-

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-- Loosen the left and right bolt -3- from the bracket -2- for the turbocharger bracket.

-- Remove the bolts -4, 5- connecting the engine to transmission. They are accessible from above.

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-- Remove the bolts -arrows- and remove the ATF pipe -1- from the transmission.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set :VAS6122  .

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-- To discharge static electricity, touch the transmission housing (without wearing gloves).

-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector from the transmission.

-- Free up the wiring harness on the transmission.

-- Slide the retainer toward the rear -arrow- and press down the release in order to disconnect the connector -2- for the steering gear.

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-- Disconnect the connector -1-.

-- Free up the wiring harness.

-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever :80-200  .

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-- Press the securing clips -2- off and remove the selector lever cable from the transmission.

-- Disconnect the connector -arrow- from the bracket and free up the wire.

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-- Remove the bolts -arrows- and then remove the heat shield from the right driveshaft.

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-- Remove the bolts -arrows- and the left driveshaft heat shield.

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-- Remove the left and right drive axles from the transmission flange shafts. Refer to DRIVE AXLE .

-- Remove the lower cover -1- from the transmission -arrow-.

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-- Connect the tools the as illustrated.

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1. Socket 21 mm for ¹ /₂ "-drive

-- Counterhold the crankshaft to loosen the dual mass flywheel bolts.

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-- Remove the six torque converter bolts -arrow- while turning the crankshaft 60° further in the direction of engine rotation.

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-- Remove the remaining engine/transmission bolts -2, 3, 6 to 11- but leave one bolt -7- installed hand-tight.

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-- Remove the starter bolt -1-.

-- Remove the starter from the transmission and leave it in the installation position.

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-- Place the Engine and Gearbox Jack :VAS6031  with the prepared Gearbox Support :T40173  on the bottom of the transmission.

-- The transmission support must be placed at the front as follows:

• The bracket -2- fits into the dual-mass flywheel on the transmission housing on the left side of the transmission.
• The transmission mount is positioned on the differential housing on the right side of the transmission. Insert a flat piece of rubber -1- in between to protect the housing.

-- Secure the transmission with a tensioning strap -1-.

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-- Remove the bolts from the tunnel crossmember -arrows-.

-- Remove the last bolt from the transmission to engine connection.

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-- Press the transmission off the engine and lower it carefully using the Engine and Gearbox Jack :VAS6931  .