Transmission, Removing: Removing

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CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- Position the front wheels so they are straight.

-- Turn off the ignition and remove the key.

-- Disconnect the ground (GND) cable -2- from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 1: Identifying Battery

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-- Remove the engine covers -1- and -2- upward -arrows-.

Fig 2: Engine Cover -1- and -2-

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-- Position the 10 - 222 A with the T40093/6 on the left and right suspension strut towers as illustrated.

Fig 3: Mounting 10 - 222 A With T40093/6 On Left And Right Suspension Strut Towers

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-- Secure the spindles 10 - 222 A /11 in the left and right engine lifting eyes.

-- Tension the engine slightly using the spindles.

-- Remove the left and right front wheels.

-- Remove the left and right noise insulation -1- inside the wheel housing.

Fig 4: Identifying Noise Insulation -1-

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-- Remove the noise insulation by loosening the fasteners -1 through 3-.

Fig 5: Identifying Noise Insulation Components

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CAUTION:

The suspension components could be damaged.

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

Do not support the vehicle on the subframe or on the subframe crossbrace (for example using a floor jack or something similar).

-- Remove the nut -1- from the power steering hydraulic line.

Fig 6: Locating Power Steering Hydraulic Line

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-- Remove the bolts -arrows- and remove the subframe crossbrace.

NOTE:

The illustration shows the installed position in a vehicle with dynamic steering.

-- Remove right and left subframe shield -1-. Do this by removing the bolts -arrows- and then removing the shield toward the inside.

Fig 7: Removing Subframe Heat Shield

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-- Remove the nuts -arrows- for the left front muffler.

Fig 8: Identifying Left Front Muffler Nuts

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-- Remove the nuts -arrows- for the right front muffler.

Fig 9: Identifying Right Front Muffler Nuts

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CAUTION:

Danger of damaging the flex joint in the front muffler.

Do not bend the decoupling element in the front muffler more than 10°.

-- Loosen the clamping sleeves -1- and -2-, push toward the rear, and remove the left and right front muffler.

Fig 10: Identifying Bolts Vehicles With Dual Exhaust System

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-- Remove the bolts -arrows-, and remove the driveshaft heat shield -A- (if equipped).

Fig 11: Identifying Driveshaft Heat Shield

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Driveshaft Bolted on the Transmission Side:

-- Remove the bolts that connect the driveshaft to the transmission by counter holding them with the T10172 and T10172/5.

Fig 12: Holding Driveshaft Using T10172

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-- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

-- Secure the driveshaft to the side.

Driveshaft Mounted on the Transmission Side:

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE or DRIVESHAFT ATTACHED ON TRANSMISSION SIDE .

For All Vehicles

-- Disconnect the connector -2- from the engine speed sensor -G28- and free up the wire.

Fig 13: Location Engine Speed (RPM) Sensor -G28-

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NOTE:

Ignore -1-.

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

Fig 14: Identifying Transmission Lower Cover

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-- Insert the T40058 guide pins as follows:

Fig 15: Identifying Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Counterhold the crankshaft with the T40058 and an angled box wrench to loosen the torque converter bolts for the clutch module at the drive plate.

Fig 16: Using Socket T40058 To Counter Hold Crankshaft

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NOTE:

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

-- Turn the clutch module over both front wheels 60° in direction of engine rotation and remove the six drive plate bolts -arrow- for the clutch module on the drive plate.

Fig 17: Identifying Clutch Module First Bolt Installation Location

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-- Remove the engine/transmission connecting bolts -7 to 11-.

Fig 18: Removing Starter Off Transmission And Leave It In Installation Position

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CAUTION:

The airbag spiral spring could be damaged.

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change the steering wheel and steering gear position. Secure the steering wheel, for example using adhesive tape.

-- Remove the universal joint bolt -arrow-. Refer to STEERING COLUMN, HANDLING AND TRANSPORTING .

Fig 19: Locating Universal Joint Bolt

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-- Press the universal joint off the steering gear and slide it all the way up.

-- Place the V.A.G 1782 under the hydraulic oil line's separating point -1- on the steering gear.

Fig 20: Placing V.A.G 1782 Under Separating Point

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-- Remove the bolts -arrows-, disconnect the hydraulic oil line -1- from the steering gear and move it to the side.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

-- Remove the bolt -1- press the retaining tab off the transmission and tilt it back -arrow-.

Fig 21: Removing Bolt Press Retaining Tab Off Transmission And Tilt It Back

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-- Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Fig 22: Removing Bolt And Secure Clutch Slave Cylinder Sideways In Engine Compartment

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CAUTION:

The clutch slave cylinder could be damaged.

Do not activate the clutch pedal after the clutch slave cylinder has been removed.

-- Remove the selector rod nut -1-.

CAUTION:

Danger of causing damage to the gearshift shaft inside the transmission.

Do not pry off the transmission shift lever -1- using a pry bar or hit it with a hammer.

Fig 23: Positioning Puller T40160 And Remove Selector Rod

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-- Install the T40160 and remove the transmission shift lever -1-.

-- Position the V.A.G 1383 A and the T40173 under the transmission and secure it with the tensioning strap -1- as illustrated.

Fig 24: Identifying Transmission Holding Fixture

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

Fig 25: Identifying Bolts & Tunnel Crossmember

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-- Lower the transmission using the V.A.G 1383 A first to dimension -a-.

Fig 26: Lowering Transmission

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Dimension -a- = maximum 100 mm.

-- Tension the 10 - 222 A spindles 10 - 222 A /11 slightly.

NOTE:

Use the VAS 5085 to get to 10 - 222 A /11 on the hoisted vehicle.

-- Remove the electrical connector -1- on the transmission range gear recognition switch -F208- using the T40138.

Fig 27: Disconnecting Connector

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-- Remove the push rod bolt -2-.

-- Remove the connecting rod bolt -3-.

-- Remove the bolts -arrows- and remove the heat shield from the right drive axle.

Fig 28: Driveshaft Heat Shield - Tightening Specification

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove the bolts -arrows- and the left drive axle heat shield.

Fig 29: Removing Bolts And Left Drive Axle Heat Shield

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove the left and right drive axles from the transmission flange shafts -arrows-.

Fig 30: Removing Left And Right Drive Axles

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-- Remove the nuts -arrows- and the bolt -1-, and push the right catalytic converter to the right side and secure.

Fig 31: Identifying Nuts, Bolts And Right Catalytic Converter

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NOTE:

The illustration shows the installation position with the engine removed.

Use the T40220 to loosen the nuts -arrow-, right catalytic converter -A- on the exhaust manifold.

Fig 32: Using T40220 To Loosen Nuts

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Secure the right catalytic converter loosely using a nut so it does not fall down.

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

Fig 33: Disconnecting Starter Electrical Connector

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-- Remove the bolt -4- and leave the starter in the installed position.

NOTE:

Ignore -2 through 3-.

-- Remove the remaining bolts -3 through 6- that attach the engine to the transmission.

Fig 34: Removing Starter Off Transmission And Leave It In Installation Position

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-- Press the transmission off the engine and lower it carefully using the V.A.G 1383 A.

If the transmission removed is being replaced, then the following components must be changed:

Right and left bracket -1- for the exhaust system EXHAUST SYSTEM, EMISSION CONTROLS .

Fig 35: Identifying Exhaust System Retaining Strap Bracket
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Tunnel crossmember with the transmission mount and transmission support. Refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .
Remove the clutch module if necessary. Refer to CLUTCH MODULE .

Fig 36: Sliding Torque Converter Carefully Onto Input Shaft
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