Sensor Module --, WITH INTEGRATED TRANSMITTERS AND SENSORS -G612-, -G632-, -G676 - AND Circuit Board 3 --, REMOVING AND INSTALLING: Removing

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Fig 1: Identifying Engine And Transmission Holder VAS6095

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Secure the transmission on the Engine And Transmission Holder VAS6095. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

-- Remove the flywheel. Refer to FLYWHEEL, REMOVING AND INSTALLING .

-- Remove the dual clutch. Refer to DSG CLUTCH, REMOVING .

-- Remove the DSG Transmission Mechatronic -J743-. Refer to MECHATRONIC, REMOVING AND INSTALLING .

-- Remove the oil pump and the suction jet pump. Refer to OIL PUMP AND SUCTION JET PUMP, REMOVING AND INSTALLING .

NOTE:

The wiring set for the sensor module must be replaced when replacing the Sensor Module --.

-- Loosen the bolts -arrows- on the wiring set for the sensor module.

Fig 2: Identifying Bolts -Arrows- On Wiring Set For Sensor Module

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-- Loosen the bolt -1-.

-- Pull the fastener in direction of -arrow A- and remove the connector in direction of -arrow B- to disconnect the connector from the Sensor Module --.

-- Remove the wiring set for the sensor module.

Fig 3: Carefully Press Connector On Sensor Module -- Completely Opposite Direction Of Arrow -Arrow B-

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-- Mount the Sensor Module Tool T40228 on the connector housing, turn it all the way to the left in direction of -arrow A- and then remove the connector housing for the Sensor Module --.

-- Remove the connector housing for the Sensor Module -- in direction of -arrow B-.

Fig 4: Mounting T40228 On Connector Housing

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-- Remove the center differential housing and center differential. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING .

-- Remove the oil guide for the input shaft -arrow-.

Fig 5: Installing Oil Guide For Input Shaft

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-- Loosen the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

Fig 6: Identifying Pinion Side Shaft Bolt

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-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the Counterhold - Side Shaft T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Tighten the Counterhold - Side Shaft T40217 on the transmission intermediate housing -arrows-.

Fig 7: Locating T40217 To Transmission Intermediate Housing

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Fig 8: Identifying Hook and Support Tool T40294

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CAUTION:

Do not use the Hook And Support Tool T40197 for the following described work procedure - There is a risk of injury.

Only use the Hook and Support Tool T40294 for this operation.

-- Remove the bolt -1- and the side shaft -2-.

Fig 9: Installing Bolt And Side Shaft

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NOTE:

The bolt has a high loosening torque.

-- Remove the spur gear -1- and needle bearing -2- from the output shaft -3-.

Fig 10: Installing Spur Gear & Needle Bearing From Output Shaft

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-- Wrap the splines for the outer drive axle with adhesive tape in direction of -arrow-, so that the inner surfaces of the suction jet pump are not damaged when removing or installing.

Fig 11: Wrapping Tape Around Input Shaft Splines

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-- Coat the tape lightly with grease.

-- Adjust the transmission housing on the engine/transmission holder so that it is vertical.

Fig 12: Identifying Holding Plate And Hook and Support Tool

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The clutch side faces down.

-- Remove the bolts -arrows- all around for the transmission intermediate housing.

Fig 13: Mating Transmission Intermediate Housing To Transmission Housing

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-- Install the Three Guide Pins - Gearbox T40288 in a distance of approximately 120° in the transmission housing bolt holes.

NOTE:

The Guide Pins - Gearbox T40288 improve the removal of the transmission housing and prevent damage to the seals and components.

-- Engage the transmission intermediate housing -1- with the wheel set on the Shop Crane VAS6100 as shown in the illustration.

Fig 14: Identifying Shop Crane VAS 6100

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WARNING:

There is the risk of an accident if the support bridge parts are loose.

Install each threaded connection on the Lifting Eyebolt 3368 and the Slide Hammer Set - Adapter 40 VW771/40 until stop to make sure they are secure.
Secure the hooks and locking pins on the Engine Sling 2024A with cotter pins.

-- Lift the transmission intermediate housing slowly and carefully off the transmission housing.

-- Place the transmission intermediate housing on a workbench.

-- Remove the bolt -arrow-, and then remove the Sensor Module -- -2-.

Fig 15: Identifying Bolt & Sensor Module

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NOTE:

The front oil catch tray -1- is engaged to the Sensor Module -- and will also be removed.

-- Release the tabs to remove the front oil catch tray -1- from the Sensor Module --.