Transmission, Removing, Vehicles With 4-Cylinder TDI Engine (Pr-TD1)

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Fig 1: Identifying Special Tools

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Special tools and workshop equipment required

Pry lever 80-200
Engine and Gearbox Jack VAS6931
Used Oil Collection and Extraction Unit SMN372500 or Used Oil Collection and Extraction Unit VAG1782
Engine Bung Set VAS6122
Counterhold - Kit - Multiple Use T10172A with Counterhold - Kit - Adapter T10172/5

Special tools and workshop equipment required

Brake Piston Retraction Tool T140142

Fig 2: Brake Piston Retraction Tool T140142
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Gearbox Support T140173

Fig 3: Gearbox Support T140173
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Preparing the Gearbox Support T140173:

Fig 4: Preparing Gearbox Support T140173 For Use

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

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

Removing

Fig 5: Identifying Battery

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-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Follow the steps when disconnecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Turn off the ignition and remove the key.

-- Disconnect the battery ground cable -2-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Carefully remove the engine cover from the retaining pins one after the other -arrows-. Do not pull sharply on the engine cover or pull it to one side.

Fig 6: Removing Engine Cover

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

-- Remove the selector lever cable ball socket -2- using the Pry Lever 80-200 from the gearshift lever.

Fig 7: Identifying Selector Lever Cable

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-- Remove the circlip -1- and free up the selector lever cable.

NOTE:

Depending on the version a lock nut can be installed instead of a clip.

-- Remove the bolts -2 through 5- connecting the engine to transmission. They are accessible from above.

Fig 8: Identifying Engine To Transmission Bolts

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NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Fig 9: Identifying Bolt & Spacer Sleeve

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-- Remove the left and right front wheels.

Fig 10: Driveshaft Cover -1-

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-- Remove the left and right driveshaft cover -1- inside the wheel housing.

-- Remove the noise insulations -1- and -2-. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

Fig 11: Noise Insulation Panels

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-- Remove the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

Fig 12: Identifying Subframe Crossbrace

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CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

-- Remove the selective catalytic reduction catalytic converter. .

-- Remove the retaining tab screw -2-.

Fig 13: Identifying Bolt -2-, Removal

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-- Press the tab -1- in -direction of arrow B- and swivel it toward the rear -arrow A-.

NOTE:

the exhaust pipe remains installed.

NOTE:

Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive service information.

Fig 14: Driveshaft Boot Hose Clamp

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-- Removing the driveshaft. .

Fig 15: Disconnecting Connector On Transmission

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Always "discharge" the static electricity before working with electric connectors. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
Do not touch contacts in transmission connector with hands.

-- Disconnect the connector on transmission by rotating screw connections counter-clockwise -arrow-.

-- Free up the wiring harness.

-- Remove the bolt -arrow- from the ATF pipes.

Fig 16: Loosening Up ATF Pipes

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NOTE:

Place a clean cloth under the separating point to catch the escaping ATF.

Fig 17: Removing ATF Pipes

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-- Remove the bolts -1- and -2- and remove the ATF pipes -3- and -4- from the transmission, then secure them at the top.

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

-- Loosen the retainer -arrow-, push the release downward to disconnect the connector -2- from the Power Steering Control Module -J500-.

Fig 18: Identifying Power Steering Control Module Connectors

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-- Free up the wiring harness.

NOTE:

Ignore -1-.

-- Remove the left and right bolts -arrows-, and the heat shield -1-, if equipped.

Fig 19: Locating Left Bolts & Heat Shield

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-- Remove the steering intermediate shaft from the steering gear and push them both upward. Refer to OVERVIEW - STEERING COLUMN .

Fig 20: Locating Universal Joint Bolt

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

Fig 21: Drive Axle Heat Shield & Bolts

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-- Remove left and right driveshafts from transmission flange shafts.

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

Fig 22: Identifying Transmission Lower Cover

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-- Remove the cap from the vibration damper.

Fig 23: Identifying Offset Open-End Wrench

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-- Counterhold the crankshaft with an angled wrench -1- to loosen the flywheel bolts on the central bolt on the vibration damper.

NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

-- Remove the 3 flywheel bolts -arrow- while turning the crankshaft 120° further in the direction of engine rotation.

Fig 24: Identifying Clutch Module First Bolt Installation Location

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-- Remove the bolt -1- from the starter.

Fig 25: Identifying Engine To Transmission Bolts

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

-- Remove remaining transmission to engine connecting bolts -6 through 10-.

NOTE:

Ignore -item A-.

CAUTION:

Danger of leaks in the ATF pan.

The Gearbox Support T140173 must not be set on the ATF pan.

Fig 26: Placing Engine And Gearbox Jack VAS 6031 Under Transmission

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-- Place the Engine and Gearbox Jack VAS 6031 with the preparedGearbox Support T140173 under the transmission.

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

The bracket -2- fits into the 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-.

Fig 27: Securing Transmission With A Tensioning Strap

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

Fig 28: Identifying Bolts & Tunnel Crossmember

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NOTE:

The illustration id shown without the Engine and Gearbox Jack VAS6931.

-- Loosen the bolt -1- for the torque support -2-.

Fig 29: Identifying Torque Support And Bolts

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-- Only lower the transmission with the Engine and Gearbox Jack VAS6931 until the torque support is completely at the bottom of its adjustment range -arrow-.

-- Tighten the bolts and position the Brake Piston Retraction Tool T140142 as a spacer as shown in the illustration.

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